102-Spiral Freezer 1.1 GUMUSDOGA

DANTECH SPIRAL FREEZER
SERVICE MANUAL
________________________________________________________________________________________
-1-
Table of Content Page
1. Spiral Freezer Description ................................................................................................... 4

1.1 System Overview ........................................................................................................... 4
1.2 Principle of Operation .................................................................................................... 4
1.2.1 How does the System work? .................................................................................. 4
1.2.2 What is “Overdrive”? ............................................................................................. 5
1.2.3 How to measure the Overdrive? ............................................................................ 6
1.2.4 What is “Spiral Belt Collapse”? ............................................................................. 8
1.3 Application ..................................................................................................................... 9
1.4 Spiral Freezer Terminology ........................................................................................... 9
2. The Components in the System ......................................................................................... 12

2.1 Drum Drive .................................................................................................................. 12
2.2 Take-up Unit and Limit Switches ................................................................................ 13
2.2.1 Take-up Drive ...................................................................................................... 13
2.2.2 Take-up Limit Switches ....................................................................................... 14
2.2.3 Belt Fault Switches .............................................................................................. 14
2.3 Evaporator and Fan Assembly ..................................................................................... 15
2.3.1 Evaporator ............................................................................................................ 15
2.3.2 Fans ...................................................................................................................... 15
3. Operating Procedure .......................................................................................................... 16

3.1 Start-Up Sequence ....................................................................................................... 16
3.2 Fault and Warning........................................................................................................ 17
3.3 Spiral Hygiene and Cleaning ....................................................................................... 17
4. Maintenance and Trouble Shooting ................................................................................... 17

4.1 Maintenance of Drive Chain ........................................................................................ 18
4.2 Maintenance of Bearing ............................................................................................... 19
4.3 Preventive measure ...................................................................................................... 20
4.3.1 Monthly ................................................................................................................ 20
4.3.2 Half-yearly ........................................................................................................... 20
4.3.3 Lubrication ........................................................................................................... 20
4.4 Typical Spiral Problem Troubleshooting ..................................................................... 21
-2-
5. Cleaning system (Optional) ............................................................................................... 23
5.1 Belt Washing System (OPTIONAL) ........................................................................... 23
5.2 CIP System (Clean-In-Place)(OPTIONAL) ................................................................ 25
6. Control Panel Operation .................................................................................................... 26

6.1 Main Screen ................................................................................................................. 26
7. Safety ................................................................................................................................. 49
7.1 Precaution while operating the System ........................................................................ 49
7.2 Precaution prior to Maintenance .................................................................................. 50
8. Illustrated Part Catalog ...................................................................................................... 51

8.1 Drive Unit .................................................................................................................... 52
8.2 Take-Up Unit ............................................................................................................... 53
8.3 Sensor & Switches ....................................................................................................... 54
8.4 Spare Parts Lists ........................................................................................................... 55
8.5 Ordering of Spare Parts ................................................................................................ 56
9. Spiral System Limitation ................................................................................................... 57

9.1 Maximum Product Load and Maximum Product Height ............................................ 57
10. Appendix (Charts & Data as to order) ............................................................................... 59

10.1 General Layout Drawing As per Order ........................................................................ 59
10.2 Technical Data- Drum & Take-up Motor .................................................................... 60
10.3 Electrical Diagram ....................................................................................................... 61
10.4 Regular Maintenance Report Form .............................................................................. 62
10.5 Corrective Service Report Form .................................................................................. 63
-3-
1. Spiral Freezer Description
1.1 System Overview
1.2 Principle of Operation
1.2.1 How does the System work?
Dantech Spiral Freezer System is the combination of Low Tension Spiral

Conveyor System and Artic Flow rapid horizontal Air flow refrigeration
system.
Low Tension Spiral Conveyor System consists of continuous friction driven

belt, which is capable of collapsing at one or both edges, or expanding on one
edge, wrapped up in a helical path- ascending or descending, around a rotating
drum. The system may be single or twin drum.
The most obvious component is the rotating drum or "cage" that forms the
core of the spiral. This is driven and acts as a friction drive for the contacting
inside edge of the belt, and performs the vast majority of the work. (See Figure
below, show most vital parts)
The drum imparts the major friction to the inner edge of the belt by rotating at
a greater speed than the belt. This is the major feature in spiral conveyor
system.
-4-
An auxiliary direct drive is installed at the discharging end of the spiral and it
is called take-up drive.
The sprocket drive has two basic functions. It determines the belt speed, and
provides "back tension"; that is, it provides the belt tension to the drum
necessary to develop a driving force for the entire spiral turns of belting. A
free floating take-up, always located following the drive sprockets, serves to
collect the entire excess belt in the system. Its travel will depend upon
temperature and loading changes. Adding extra weight only serves to increase
the overall system tension, and is undesirable.
1.2.2 What is “Overdrive”?
There is a very important relationship between the speed of the belt and the
surface speed of the cage or drum acting on the inside edge of the belt in the
spirals. There must be a "positive" slippage; that is, the drum surface must
move faster than the inside edge of the belt. We call this OVERDRIVE.
This is necessary, as in any friction drive, in order to develop a driving force

for the belt. With no overdrive, or worse, negative slipping, the drum would
act as brake, severely damaging the belt. Overdrive must exist for proper
operation of this conveyor.
The proper amount of overdrive is not a precise value, and is dependent on the
local value of friction between the belt and the cage and the support rails. Any
changes in temperature, humidity, or the presence of oil or other contaminants,
will affect the value of the optimum overdrive. Some experimentation thus
may be necessary. Low overdrive will not allow full development of the cage
-5-
driving force, producing very high belt tension. Avoid this situation at all
costs. It may result in permanent belt damage
Increasing the overdrive beyond a practical limit will not be harmful except
that it tends to wear the cage surface and belt edge more rapidly.
The upper limit of overdrive is defined by the visible onset of "surging" of the
belt; that is, a jerky or stop-and-go motion. Even if this causes no damage to
the belt, it probably will disrupt the conveyor product. This is usually
objectionable to the user. Belt tension is very low at this point.
Thus the "optimum" overdrive could be defined as that which produces the
maximum surging that can be tolerated. If smoothness is critical to your
operation, decrease the overdrive slightly until the surging is no longer
troublesome. Remember that a high tension belt (low over drive) operates very
smoothly but long term belt damage can result through fatigue failure.
1.2.3 How to measure the Overdrive?
It is important to measure the overdrive of your system often, and it should be

the first thing to do if you suspect that its performance is not as it should be.
See Figure 2. Stand facing the spiral section at a convenient well lighted area.
Identify any particular cage bar that can be easily spotted during rotation, or
provide such a mark by spray paint, marker, etc (Dantech has provided the
Black Nylon Cage bar). Place an object on the belt at the inner edge in line
with this bar and allow the object to make a full revolution on the belt (it will
return on the next tier of course). At the instant it completes the 360° of travel,
measure or estimate the distance between it and the marked cage bar which
has hopefully already passed your station). This advance is the OVERDRIVE.
If the speed is too great to permit an actual measurement, or if cannot estimate
it within an 25 mm or so, count the cage bar spaces as they go by and multiply
by the known spacing
The belt pitch will become longer from internal wear over a period of time,
which will cause the original overdrive as preset by the installer to decrease,
causing a gradual increase in belt tension. If the belt begins to flip up on the
outside edge, or hangup on the inside edge at say the top of the down spiral, or
-6-
if the belt begins to show fractures from fatigue failure, then the overdrive
probably needs to be re-established NOW!
If you have included overdrive recorded in your normal maintenance routine,

you would have detected this trend and corrected it BEFORE any of the above
symptoms appeared. Therefore we highly recommend this procedure.
As the percentage of the systems "OVERDRIVE" has a major influence of the

tension of the whole system, it is of importance that only qualified people do
the adjustment.
As to our experience, the existence of OVERDRIVE can seem unnatural to

many people operating the machine. For that reason it is very important that
operators are informed about the importance of overdrive.
In summary, include recorded overdrive measurements as part of your

maintenance procedures. Remember that excessive overdrive produces the
lowest tension but also creates undesirable surging. Insufficient or low
overdrive produces high belt tensions that can be dangerous to the operation of
this system. It is this condition that you are checking for and should avoid.
To recapitulate what we discussed above, the procedure to measure

Overdrive is as below:
1. Face the spiral at a convenient point and identify the black cage bar.
2. While the spiral is rotating, place an object on the inside edge of the
belt inline with that cage bar. (Use the appropriate caution working
around moving equipment)
3. After one revolution of the “product”, note how far the “Black cage
bar” is in front of the product (product will appear on the next tier)
previously placed on the belt. This distance can be expressed in
equivalent of cage bars passed or measured in mm.
4. Eg. If the overdrive distance = 500 mm (4 cage bar with 125 mm

Pitch) –Drum Diameter = 2300 mm: Then,
The Overdrive Ratio = (Total Dist Travel by Cage/ Dist Travel by

product)
The Overdrive Ratio = {(Diameter of Drum x 3.14)+(500)}/ (3.14
x 2300)
The Overdrive Ratio = {(2300 x 3.14)+(500)}/ (3.14 x 2300)
The Overdrive Ratio = 1.06= 106 %
-7-
 If OVERDRIVE increase: belt tension decrease, resulting in more
jerking belt movement.
 If OVERDRIVE decrease: belt tension increase, resulting in more
smooth running movement.
1.2.4 What is “Spiral Belt Collapse”?
While the system is conveying the product, the product density on the belt
may vary by means of two ways. Firstly, even though products are densely
placed at the infeed conveyor, when they are transferred to the spiral belt, they
will become sparsely populated because of different speed between infeed
conveyor and spiral. It is crucial to consider these conditions in order to
select the correct loading pattern. It can be seen in the figure below as (A)
and (B). Secondly, when spiral belt start turning around the drum, the distance
between each product will change again. Refer to (C) and (D) in figure. This is
because of belt collapse at one edge and remains at other edge. This
phenomenon is called Spiral Belt Collapse. Note: That B>A, C>B and D<B.
-8-
1.3 Application
Since Spiral Freezers are using the vertical space available, they are quite
attractive in the factory with limited floor space.
Spiral Freezers are currently used in the following industrial applications such as:
1. POULTRY INDUSTRY - chicken parts, chicken patties, chicken nuggets,

marinated chicken chunk, breaded chicken parts
2. RED MEAT INDUSTRY - meat patties, meatballs, raw hamburger,

breaded fried cuts
3. SEA FOOD INDUSTRY - breaded fish sticks or patties, raw and cooked
shrimp, fish fillets, scallops, whole fish.
4. BAKERY PRODUCTS - pizzas, pies, cookies, pasta, bread dough.
5. PREPARED FOODS - packaged food in trays, shrimps in trays, ice cream

cups, products requiring a long retention time
1.4 Spiral Freezer Terminology
Belt Stretch: Elongation of the belt due to physical wearing, not

to be confused with thermal elongation.
Belt Tension: The force that can be measured on the outer edge of
the belt, which is a function of the overdrive on the
cage.. When this tension gets too high, the outer
edge of the belt wants to lift upward (flipping),
causing potential problems.
Collapse Factor: A varying factor applied to the belts being used in a

spiral. This collapse factor affects belt lengths in a
system, as well as being affected by varying cage
diameters. It is also know as Turn Ratio, the ratio of
inside turn radius to the belt width. (It is normally in
the range 1.7 ~ 2.2)
Collapse Point: The point where the belt enters the cage and changes
state from straight to radius.
Discharge: The point where the product leaves the spiral.
Drum: The central drum or tower which is usually a caged

construction with vertical driving bars.
Drum Drive: A motor and gearbox assembly directly driving the

drum centre shaft which provides the central moving
-9-
force to turn the cage, also called the cage drive, or
main drive.
Drum Drive Chain: The chain that is used to turn and drive the central
cage or drum.
Flipping/ Belt Lifting: Typically referred to the belting either lifting on the
outer edges, or the need to turn over the belt in the
system in order to evenly wear on each side on a
usage basis.
Frame Assembly: The structural frame work which everything else in

the spiral is attached to.
Grid Belting: Metal belting with specific characteristic of strength,

weight and application performance.
Infeed: The point where the product enters the spiral
Lubrication: Required for drive assembly, selected drive chains,

and selected track or belt in given applications that
use metal belts.
Maximum Product Height: Dimensional number that should not be exceeded

for proper clearances.
Mobius Flip: Term applied to a method of continuous turning the

belt over as it travels through the spiral system.
Usually associated with equalizing wear on both
edges of the belt.
Overdrive: The additional distance, as the surface of the drum

has achieved, while the belt has turned a full 360° is
determined as "Overdrive" measured in percentage.
E.g. if a "Overdrive" of 125% is determined, it
means in practical terms that the drum has turned
1¼ whilst the belt has turned only 1 round.
Return: Layout of path of belt from the exit roller to the

infeed roller. This includes take-up drive plus take-
up.
Spiral: Description of belt pattern, more correctly described

as helical, but taken from common usage as a
"spiral".
Supports: Generally describing the structure supporting the

belt with particular attention paid to the friction
surface over which the belt drags.
-10-
Take-up: Either comprised of a separate small motor and
reducer coupled to the belt sprocket drive shaft, or a
mechanical linkage between some element of the
drum drive and the belt sprocket drive shaft.
Tier: A 360 degrees element of the spiral either ascending

or descending one level.
Tier pitch: Vertical distance between tiers.
Under Tensioning: A state where there is too little drive force being
applied to the cage/belt interface causing uneven
belt surging.
Updrum/Downdrum: Describing systems with either ascending or

descending belt paths.
-11-
2. The Components in the System
2.1 Drum Drive
The drum consists of a vertical hollow section centre shaft to which top, bottom
and centre support angle rings are attached by radial spokes.
The main friction driving force occurs between the inner edge of belt and the wear
strips.
The centre shaft is mounted between the top and bottom bearings, centrally
located on the top and bottom frames. The whole drum is rotated by means of a
chain drive from the main gearbox drive unit.
The drum is driven from an electric motor coupled via a chain drive. The output
shaft of the gear-motor is mounted with a sprocket wheel and it drives the drum
directly from below, with the forces evenly distributed to the drum. The motor
speed is controlled from a frequency inverter in the control panel.
-12-
2.2 Take-up Unit and Limit Switches
2.2.1 Take-up Drive
The take-up drive is established through a separate horizontally mounted

motorised variable speed gear unit, coupled directly to the shaft.
The belt is held in tension over the belt drive sprockets, (ensuring positive
tooth to belt engagement), by the use of a free-floating counterweight,
supporting a belt loop within the take-up frame. The loop allows for variations
in belt length which may arise from temperature or product loading conditions.
System speed is given as a process time i.e. time taken from product entry to
discharge and is displayed by the freezing time indicator mounted on the front
door of the control panel.
-13-
2.2.2 Take-up Limit Switches
Proximity switches are mounted above the take-up frame and below the
counterweight. This system will protect the belt for excessive belt tension.
2.2.3 Belt Fault Switches
Further protection to the system is provided by a proximity switch mounted

below the outer edge of the belt which will stop the machine in the event of
excessive tension in the form of belt lift during running.
If the machine is stopped for this reason, the cause should be thoroughly
investigated and rectified before attempting to restart the machine.
-14-
2.3 Evaporator and Fan Assembly
Air is blasted through an evaporator coil in a horizontal direction over the full
height of the product run by the use of axial flowfans.
The main framework is sheeted and baffled in such a way as to ensure even
airflow over product throughout the system before being allowed to return
between the framework and insulated cabinet walls back to the fan suction.
Some sheeting panels are formed and hinged to allow access to the belt for
observing product run, cleaning down and maintenance.
2.3.1 Evaporator
Evaporators are either of galvanised steel construction (for R-717 and freon
applications) copper and aluminium (for freon only) or stainless steel with
aluminium or stainless fins. Fin pitching decreases from "air on" to "air off"
side progressively.
Evaporators are designed for either hot gas, water, or combined gas and water
defrost, with built in defrost catch trays. Defrost is usually required once per
24 hours, and is a most important factor in the maintenance procedure.
Thorough and total defrosting of the entire evaporator block is essential to
prevent damage to fins and to maintain freezing efficiency.
A thorough visual check should be made to ensure the finned area is totally
free of any ice before restart.
The water defrost supply line should be fitted with a drain ensuring the water
within the line is drained away from the freezer enclosure. Failure to open the
drain after defrosting will result in bursting of water pipes within the
enclosure.
2.3.2 Fans
The axial flow fans are positioned to obtain optimum air distribution over the
face of the evaporator. Fans are set to sequentially start in 4 second delay on
start up for Dantech Spiral freezer.
-15-
3. Operating Procedure
3.1 Start-Up Sequence
As we all know, moisture is the mother of almost all problems in freezer. Moisture
can be lodging in the freezer because of humid air infiltrating into the Spiral
freezer or/and because of product bringing the moisture into the freezer and
probably of other causes as well. And the difference in air density between the hot
air outside and the cold air inside the system also drives the humid air into the
system continuously. To avoid the problems, the air must be dried before its
moisture can condense on the rails, drum, take-up and others
Serious damage might be taken place if the machine is started in this situation.
So, under this circumstance, it better to start the cooling fan first, prior to running
the Spiral Drum.
The start-up and running procedure may vary for individual systems, but the
following course is considered satisfactory for the majority of the spiral freezing
system:
1. Visually inspect belt, ensuring it is free from foreign matter (i.e. hand tools,
etc) laying on it.
2. Ensure that no fault alarm is ON.
3. Start system drive at low speed and run belt through at least one revolution,
keeping a close watch throughout the system until a smooth running
condition is maintained.
4. Start up refrigeration plant according to installer/manufacturers
recommendation.
5. Start fans (sequential start sequence) and observe "fan running" lights are
being illuminated.
6. Pull cabinet air temperature down as required. A minimum pull down time of
30 minutes is required to allow for thermal contraction.
7. When required cabinet air temperature is reached, adjust the belt speed to
production run.
8. Ensure product loading is as specified, and remember that it is very wrong to
assume that overloading of product can make up for lost time or production.
Normally, adjustments to the system should not be necessary.
WARNING:
It is important that once a spiral freezer has been pulled down to a

certain temperature, it should not be allowed to rise above -10°C.
The machine must not be allowed to partially defrost.
-16-
The machine can of course be left with the belt and fans running with no
refrigeration, but a close watch should be kept on the cabinet temperature.
However, if the temperature rises too high and refrigeration cannot be applied,
then defrosting should be applied and let the machine dry before restarting.
If it is desired to hold the cabinet temperature down overnight with or without
product in the cabinet, then refrigerant flow must be maintained through the
evaporator coils and at least one fan per coil block must be run intermittently
between temperature limits. It is recommended that the air temperature within the
cabinet be kept at a maximum of -25°C and a minimum of -40°C.
3.2 Fault and Warning
The majority of belt running faults will be traced back to some form of obstruction
to the belt. If the belt should become obstructed, the result will lead to excessive
tension within one section of the system and, on the other hand, excessive
slackness in other end.
A variation in belt tension within the system while running results in a movement
of the floating roller that runs within the take-up frame. If this movement becomes
excessive, the machine is stopped by the top limit switch mounted on the take-up.
3.3 Spiral Hygiene and Cleaning
Belt tension can be considerably increased by foreign matter on the belt or belt
rails. The belt and rails must be cleaned thoroughly and regularly. Otherwise, the
belt tension will increase, eventually reducing the life of the belt and possibly
leading to malfunction of the system.
The spiral conveyor system MUST be kept clean at all times for reasons of
hygiene and system life.
The spiral is based on the principle of a low tension drive system. The materials
used in the machine have been selected to ensure maximum life and efficiency.
It is crucial to keep the belt and all sliding faces clean at ALL times, and be free
from build up of dirt and fragments of product. The worst contaminants are
sugars, oils, fats and chocolate products.
Allowing contamination of parts and surfaces to persist will result in a

considerable increase in belt tension and consequently cause the system
deterioration. It will become a factor for more downtime and affect the revenue of
company.
Lack of compliance to this general instruction will invalidate our guarantee.
4. Maintenance and Trouble Shooting
-17-
4.1 Maintenance of Drive Chain
To minimize the wear and tear of Drive Chain and sprocket, it is advisable to
lubricate the Chain, Sprocket and Drive Shaft regularly. Please refer to Dantech
for the specification of Lubricant.
1. Check lubrication
Be sure that the lubrication schedule is being followed. If the chain is covered
with dirt and debris, clean the chain with kerosene and re-lubricate it.
2. Check Chain Tension
Check chain tension and adjust as needed to maintain the proper sag in the slack
span. If elongation exceeds the available adjustment, make some adjustment in
Dantech Chain Tension Unit.
3. Check Chain Wear
Measure the chain wear elongation and if elongation exceeds functional limits or
is greater than 3% (0.36 inches in one foot or 30mm in one meter) replace the
entire chain. Do not connect a new section of chain to a worn chain because it may
run rough and damage the drive. Do not continue to run a chain worn beyond 3%
elongation because the chain will not engage the sprockets properly and it may
damage the sprockets.
4. Check Sprocket Tooth Wear
Check for roughness or binding when the chain engages or disengages from the
sprocket. Inspect the sprocket teeth for reduced tooth section and hooked tooth
tips. If these conditions are present, the sprocket teeth are excessively worn and
the sprocket should be replaced. Do not run new chain on worn sprockets as it will
cause the new chain to wear rapidly. Conversely, do not run a worn chain on new
sprockets as it will cause the new sprockets to wear rapidly.
5. Check Sprocket Alignment
If there is noticeable wear on the inside surface of the chain roller linkplates, the
sprockets may be misaligned. Realign the sprockets as outlined in the installation
instructions to prevent further abnormal chain and sprocket wear.
6. Check for Drive Interference
Check for interference between the drive and other parts of the equipment. If there
is any, correct it immediately. Interference can cause abnormal and potentially
destructive wear on the chain or the interfering part. If the edges of the chain
linkplates impact against a rigid part, linkplate fatigue and chain failure can result.
Check for and eliminate any buildup of debris or foreign material between the
chain and sprockets.
-18-
A RELATIVELY SMALL AMOUNT OF DEBRIS IN THE SPROCKET
ROLL SEAT CAN CAUSE TENSILE LOADS GREAT ENOUGH TO
BREAK THE CHAIN IF FORCED THROUGH THE DRIVE
7. Check for Failure
Inspect the chain for cracked, broken or deformed parts. If any of these conditions
are found, REPLACE THE ENTIRE CHAIN, even though portions of the chain
appear to be in good condition. In all likelihood, the entire chain has been
damaged.
4.2 Maintenance of Bearing
To keep the Dantech Spiral System working properly, all the bearings at the
Infeed unit, Drum drive unit, and Take-up must be properly maintained.
The fundamental purpose of a bearing is to reduce friction and wear between

rotating parts that are in contact with one another in any mechanism. The length of
time a machine will retain its original operating efficiency and accuracy will
depend upon the proper selection of bearings, the care taken while installing them,
proper lubrication, and proper maintenance provided during actual operation. A
well-planned and systematic maintenance procedure will assure extended
operation of the machine. Failure to take the necessary precautions will generally
lead to machine downtime.
1. Tips for maintenance
1. Visually inspect belt/ chain, ensuring it is free from foreign matter (i.e. hand
tools, etc) laying on it.
2. Additional supply of grease should be given to the newly procured motors
before they are started running, or to the motors have stopped running for
more than 2 months before they are re-started for running.
3. After motors having started running, additional grease should be supplied at
regular intervals.
4. The discharged grease should be removed timely.
2. After stopping running for a long period (more than 2 months) :
1. Visually inspect belt, ensuring it is free from foreign matter (i.e. hand tools,
etc) laying on it.
2. Make sure to checks described in item 1 and 4 have been completed.
3. After started running, grease should be injected at once.
4. Temperature rise around bearings after started running.
5. Loudness and tone of bearing noise.
6. Noise and vibration of the motor.
7. Vibration of the bearing.
8. Maintenance of Gear Box.
-19-
4.3 Preventive measure
To keep the system running smoothly for the best result of production rate, regular
preventive measures are necessary. However, these maintenances should be
carried out by trained staff.
4.3.1 Monthly
1. Inspect the belt damages. To do this, run the spiral for at least one
complete cycle and examine whether there are some abnormal
conditions. If so, replace the damaged belt immediately.
2. A block of soft material (i.e. Polystyrene) cut to maximum product height
and effective belt width should be run through the system from infeed to
exit point, ensuring product clearance is maintained.
3. Inspect all belt support structures for wear and tear.
4. Inspect all belt sprockets and idlers for wear and alignment. Replace or
adjust if necessary.
5. Check the drive chain is properly tensioned and running well.
6. Check oil levels in gear box units. Top up if necessary. Also grease if
necessary.
7. Check all shafts and couplings for alignment and also check tightness on
grub screws.
8. Check tightness of tie rod bolts inside drum.
9. Check that isolator is locked off before going inside drum.
4.3.2 Half-yearly
Check oil in all gearboxes after cleaning filter elements.
4.3.3 Lubrication
1. Lubrication at the Top and Bottom Rod at the Drum- Please refer to
the drawing below for daily, weekly and yearly lubrication of the
machine.
-20-
2. Lubrication of Drive Chain- Drive chain consists of a series of
connecting traveling metallic bearings, which must be properly lubricated
to obtain the maximum service life of the chain. Although many slow
speed drives operate successfully with little or no lubrication beyond the
initial factory lubrication, proper lubrication will greatly extend the useful
life of every chain drive. The chain drive requires lubrication for six
purposes.
1. To resist wear of the pin-bushing joint.

2. To cushion impact loads.
3. To dissipate any heat generated.
4. To flush away foreign materials.
5. To lubricate chain-sprocket contact surfaces.
6. To delay rust or corrosion.
4.4 Typical Spiral Problem Troubleshooting
-21-
2. High Tension:
a. Insufficient overdrive
b. High friction contamination by product or environment
c. Insufficient belt drive input resulting in localized high tension, additional
drives required.
Any of the above can result in BELT FATIGUE BREAKS i.e. cracked
welds, broken links.
2. Mesh Overlay (Wiremesh belt top) Damages:
a. Abuse by operators
b. Belt jumping off sprockets
c. Ice build-up on rollers etc.
Mesh damage can result in WIRE FATIGUE BREAKS and prevent

proper movement of links due to wire interference.
3. Product Jam-ups:
a. Overloading at infeed.
4. Belt edge damaged
a. Belt contact on framework

b. Worn guides
c. Belt flipping
d. High tension
Belts have a tendency to "SWING WIDE" as they exit the spiral cage.
5. LONG CONNECTOR ENDS i.e. joining rods:
a. Threaded connector ends not trimmed when belt was joined.
6. MIS-ALIGNED SPROCKETS:
a. Concentrated wear on belt components.
7. POOR MAINTENANCE
a. Bad bearings
b. Worn/missing wear strips
c. Male-adjusted safety switches etc.
8. Hygiene/contamination problems
-22-
The build up of contaminants may not be visible by eye but their
presence can be indicated possibly by the following:
a. An increase in the amount of belt in the slack loop take-up unit. As the
contaminants increase, so will the length of slack belt, causing nuisance
tripping of the take-up switch. It is so easy to move the switch and ignore
the underlying problem. To do so is false economy and potentially very
damaging. If the switch trips, it is essential to investigate the problem and
correct it. If the problem is high belt to rail friction, cleaning the system
will result in far less belt in the take-up loop, therefore more belt around
drum.
b. It will be more difficult to pull the belt radially outwards away from the
drum on a dirty machine because the edge links will be higher tension
than normal.
c. When Take-Up Weight bounce violently or exit belt jerk suddenly, it

might be because of some obstruction, and if it is detected by limit-
switch, the machine will stop. Do not adjust the limit switch to overcome
the problem. The limit switch is a warning that something is restricting
the belt path - investigate and remove the obstruction. If an obstruction is
not found, the problem may be a build up of contaminants between the
belt and the rails.
d. If there is an increase in ampere of either the take-up or drum drive motor

amps, it indicates that a higher driving resistance (friction) within the
system.
e. Grey or black marks may be seen on the sides of the plastic support
strips. Similar deposits may be noticed where the belt components
interlock.
If any of the above events occur, it is recommended that the belt and
system need to be cleaned.
5. Cleaning system (Optional)
5.1 Belt Washing System (OPTIONAL)
Dantech belt washing system is absolutely optional and Dantech will provide it
only when it is necessary to meet the customer’s requirement.
For a typical Belt Washing System, it is usually located at the inlet of Spiral
System and cleanses the returning belt before it is ready to be loaded with product.
It is usually comprised of the following steps:
-23-
(1) submerging the returning belt to the water (warm water or water with
foam, depending on the application)
(2) The next step is, using spray water, to clear the dirt at the belt
(3) Getting rid of the water droplets by shaking the belt
(4) Drying the belt by hot air jet.
-24-
5.2 CIP System (Clean-In-Place)(OPTIONAL)
Dantech belt CIP (Clean-In-Place) system is also an optional feature and it comes
with following steps:
- Step (1), pump+Water , (It is water spray washing)

- Step (2), pump+Chemical, (Cleaning with chemical)
- Step (3), pump+Rinse+Water (Cleaning the chemical)
- Step (4), pump+Disinfection (Neutralizing)
- Step (5), pump+Rinse+Water (Total cleaning)
- Step (6) Dryer (As per requirement)
- By Setting to Air Valve to turn on, the system will create the Air Foam.
- Each zone will be cleaned in turn at each step. Each CIP valve will represent
each cleaning zone. The number of Zone might be different for the different
spiral system.
To operate and setting adjustment of the CIP, please refer to the

Chapter 6.
-25-
User Interface Operation Manuals For Spiral Freezers
6. Control Panel Operation
6.1 Main Screen
Touch Screen User Interface

Operation Manuals For
Spiral Freezers
Version 1.1
P26250 (P25150)
Dated June 08
- 26 -
CONTENTS
Figure 1. Dantech Logo Screen
Figure 2. The Main Operation Screen
Figure 3. Password to go into Service page
Figure 3.1. Service page
Figure 3.1.1. Overdrive Setting Page
Figure 3.1.2. Hour Run Record Page
Figure 3.1.3. Cooling Fans Night Mode Setting
Figure 3.1.4. Defrost Timing Setting
Figure 3.1.5. Tower Light Door Heater Setting
Figure 3.1.6. Sensor Delay Time Page
Figure 3.2. Password to go into higher level Service page
Figure 3.2.1. Temperature Calibration Page
Figure 3.2.2. Overdrive Maximum/Minimum Setting Page
Figure 3.2.3. Data logging Page
Figure 3.2.4. Motor Data Page
Figure 4. On/Off Operation Page
Figure 5. Program Page
Figure 6. Alarm Page
- 27 -
Figure 1. Dantech Logo Screen

This is an easy operation soft touch screen, do not use sharp object, use finger only when you
need to operate this.
Select the language go to next page, Figure 2.
- 28 -
Return to Figure 1
Refer to Figure 7
Refer to Figure 3
Refer to Figure 4 Refer to Figure 5
Figure 2. The Main Operation Screen

Here the monitoring liquid temperatures referring the inlets of the ammonia. The room’s
temperature is referring to the spiral’s room monitoring temperature.
The freezing time can be change and on/off operate here. The freezing time program can be
select by Program Page setting (Figure 5) and its recipe name will be shown here.
Set Program on the Program Number box.
- 29 -
Spiral freezer’s cooling fans can be operated with two (2) types of modes, Auto and Night. In
Auto mode, the fans will turn on one by one with a interval of 5 seconds to prevent currents
surge. This mode is use for production running. In the night, products might need to store in
the freezer without rotating the freezer belt with a preset control temperature. This can be
achieved by setting the freezer to the night mode. During the night mode, temperature will be
control by activate the freezing valve and cooling fans can be pre-selects.
There is an IQF tunnel integrated with it.
- 30 -
Figure 3. Password to go into Service page
Different password are issued to different customer, please refer to Dantech on the password.
- 31 -
Figure 3.1. Service page
- 32 -
Figure 3.1.1. Overdrive Setting Page
The drum overdrive is the overrun percentage of the drum’s motor.
- 33 -
Figure 3.1.2. Hour Run Record Page
The total production runs time.
- 34 -
Figure 3.1.3. Cooling Fans Setting
Here, the manual mode, allow the user to operate the spiral’s fans individually for
troubleshooting.
- 35 -
Figure 3.1.4. Defrost Timing Setting
Defrost delay time is the time set to off the defrost relay.
Freezing delay time is the time set to on the freezing relay.
- 36 -
Figure 3.1.5. Tower Light Door Heater Setting
The warning temperature setting is the set value on the production temperature. With the
room temperature reach below this value it will in term trigger the green tower light,
informing the user temperature is ready for production used.
The door heater will be activated if the temperature is reach below this preset value.
- 37 -
Figure 3.1.6. Sensor Delay Time Page
The sensitivity or delay trigger time of the sensors will be able to set over here.
- 38 -
Figure 3.2. Password to go into higher level Service page
Different password are issued to different customer, please refer to Dantech on the password.
WARNING ! Do Not Change the Motor Data!!

Changing of motors data will affect the performance of the machine.
This setting should only be set by qualified service personnel!
- 39 -
Figure 3.2.1. Temperature Calibration Page
Each temperature monitor feedback can be offset here.

Procedure on offsetting is conduct using a calibrated temperature probe measuring the target
room and offset the different. The display will change accordingly on the operation page
Figure2.
- 40 -
Figure 3.2.2. Overdrive Maximum/Minimum Setting Page
The value of the Drum overdrive and the infeed speed percentage can be cap locked by
setting the maximum and minimum limits. This is to preventing someone enter a value that
resulting unnecessary problem.
- 41 -
Figure 3.2.3. Data logging Page
During the production run, information data such as conveyors speed, temperatures will be
log into the touch screen memory. The logging time interval can be set. The interval setting
will affect the logging time in term of memory size.
Logged data can be saved into the CF card, insert the card at the rear of the touch screen and
press the Save to CF Card button.
- 42 -
- 43 -
Figure 3.2.4. Motor Data Page
WARNING ! Do Not Change the Motor Data!!

Changing of motors data will affect the performance of the machine.
This setting should only be set by qualified service personnel!
- 44 -
Figure 4. On/Off Operation Page
This is an operation page. The belt glazer conveyor belts and the water pump can be control
on/off manually. With the IQF tunnel, there are few conveyors belts and cooling fans to be
controlled.
- 45 -
Figure 5. Program Page
The machine is allowed to pre-program the speed/time of the freezer.

These pre-program features allow different products to be able to run on the fly.
There are (100) programs available. The user need to find out the optimize speed/time
Of each individual products and set those into this speed program setting page.
On production, user only needs to select the correct program to be run on this page.
- 46 -
Figure 6. Alarm Page
- 47 -
Alarm Messages/Remedy:
200: Emergency Stop!

-Check Emergency Stop button pressed
201: Spiral Cooling Fan 1 Overload !

-Thermal overloads trips. Check these fan current, possible jams or wire loose. Else motor
faulty.
213: Water Pump Overload !

247: CIP Pump Overload !
207: Drum Overload !
243: Infeed Overload !
208: Takeup Oveload !
220: Belt Glazer Overload !
-Thermal overloads trips. Check these respective motor current, possible jams or wire loose.
Else motor faulty.
24: Drum Inverter Error !

244: Infeed Inverter Error !
225: Takeup Inverter Error !-Motor drew too high current. Possible jams or load too big.
233: Takeup Sensor Activated !

-Belt lift at take-up motor position.
234: Drum Chain Sensor Activated !

238: Collumn 7A Sensor Activated !
-Belt lift at respective position. Or products stuck at the respective position.
- 48 -
7. Safety
7.1 Precaution while operating the System
1. When freezer is running at low temperature, DO NOT enter inside without

informing any of coworker.
2. DO NOT leave tools or loose equipment on the belt, as this could cause
damage if the machine is started.
3. DO NOT leave tools or loose equipment near the fan entries as they could be
drawn into the fans causing serious damage to the fans and coils. Refrigerant
loss is also possible which might lead to loss of production.
4. DO NOT stand on the belt.
5. Keep ALL guards in place.
6. In case of emergency, press the Emergency Button as shown below:
NOTE:
It is important that maintenance personnel are aware of the importance of this

manual and ensure to receive adequate training for the operation and
maintenance of the machine.
- 49 -
7.2 Precaution prior to Maintenance
1. DO NOT leave tools or loose equipment on the belt, as this could cause
damage if the machine is started.
2. DO NOT leave tools or loose equipment near the fan entries as they could be
drawn into the fans causing serious damage to the fans and coils. Refrigerant
loss is also possible which might lead to loss of production.
3. DO NOT stand on the belt.
4. SAFETY SWITCHES: These are only helpful ONLY when operating
correctly. Check AT LEAST once weekly.
5. Always lock off isolator when working inside the freezer or on powered
equipment.
6. NEVER go inside the drum unless the isolator is locked off.
7. A relief valve should always be fitted to bypass the coil isolating valves.
8. Remember that the coils contain a refrigerant which may leak. When working
inside the freezer, ensure that you have a quick and easy exit.
- 50 -
8. Illustrated Part Catalog
- 51 -
8.1 Drive Unit
- 52 -
8.2 Take-Up Unit
- 53 -
8.3 Sensor & Switches
See the spare parts list for specific sensors & switches.
- 54 -
8.4 Spare Parts Lists
- 55 -
8.5 Ordering of Spare Parts
To ensure expedient supply of ordered spare parts, please specify following when
placing an order.
1. Order No. (See order confirmation)
2. Item No. (See order confirmation)
3. Name and type of spare part
4. Number of requested spare parts
5. Delivery address
7. Invoice address
8. Your phone / fax No.
Our Address:
Dantech Food Systems Pte Ltd

31 Loyang Crescent
Singapore 509013
Email : dantech@dantech.com.sg
Website : www.dantech.com.sg
Tel : 65 6281 2878
Fax : 65 6281 2908
- 56 -
9. Spiral System Limitation
9.1 Maximum Product Load and Maximum Product Height

Maximum Product Loads for Spiral Belt VICO FLEX HD-63-
Belts 274-16
Drum Diameter 2300mm

Belt Width Radius Belt Weight Max.Product Weight
Belt Type
[mm] Factor [kg/m] [kg/m] Stretched
510 2.25 VICO-FLEX-HD 7.80 28.5
660 1.74 VICO-FLEX-HDRR 9.70 23.5
712 1.62 VICO-FLEX-HD/Std 10.35 22
762 1.51
VICO-FLEX-HD
914 1.26
Small Radius
1000 1.15

Belt Type
510 2.45 VICO-FLEX-HD 7.80 26.5
660 1.89 9.70 22
VICO-FLEX-HDRR
712 1.76 10.40 20
762 1.64 VICO-FLEX-HD/Std 10.95 19
914 1.37 VICO-FLEX-HD
1000 1.25 Small Radius

Belt Type
510 3.14 7.80 20.5
660 2.42 VICO-FLEX-HD 9.70 17
712 2.25 10.40 15.5
762 2.10 11.00 14
VICO-FLEX-HDRR
914 1.75 13.00 11
1000 1.60 VICO-FLEX-HD/Std 14.15 9
- 57 -

Belt Type
510 3.48 7.80 18.5
660 2.69 9.70 15
VICO-FLEX-HD
712 2.49 10.40 14
762 2.33 11.00 13
914 1.94 13.00 9
VICO-FLEX-HDRR
1000 1.78 14.20 7

Belt Type
510 4.12 7.80 15
660 3.18 9.70 12
712 2.95 VICO-FLEX-HD 10.40 11
762 2.76 11.00 10
914 2.30 13.00 6.5
1000 2.10 VICO-FLEX-HDRR 14.20 5
- 58 -
10. Appendix (Charts & Data as to order)
10.1 General Layout Drawing As per Order
- 59 -
10.2 Technical Data- Drum & Take-up Motor
- 60 -
10.3 Electrical Diagram
- 61 -
10.4 Regular Maintenance Report Form
- 62 -
10.5 Corrective Service Report Form
- 63 -

102-Spiral Freezer 1.1 GUMUSDOGA

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

102-Spiral Freezer 1.1 GUMUSDOGA

Uploaded by

Copyright:

Available Formats

DANTECH SPIRAL FREEZER

1. Spiral Freezer Description ................................................................................................... 4

2. The Components in the System ......................................................................................... 12

3. Operating Procedure .......................................................................................................... 16

4. Maintenance and Trouble Shooting ................................................................................... 17

6. Control Panel Operation .................................................................................................... 26

8. Illustrated Part Catalog ...................................................................................................... 51

9. Spiral System Limitation ................................................................................................... 57

10. Appendix (Charts & Data as to order) ............................................................................... 59

1.1 System Overview

1.2 Principle of Operation

1.2.1 How does the System work?

Dantech Spiral Freezer System is the combination of Low Tension Spiral

Low Tension Spiral Conveyor System consists of continuous friction driven

1.2.2 What is “Overdrive”?

This is necessary, as in any friction drive, in order to develop a driving force

1.2.3 How to measure the Overdrive?

It is important to measure the overdrive of your system often, and it should be

If you have included overdrive recorded in your normal maintenance routine,

As the percentage of the systems "OVERDRIVE" has a major influence of the

As to our experience, the existence of OVERDRIVE can seem unnatural to

In summary, include recorded overdrive measurements as part of your

To recapitulate what we discussed above, the procedure to measure

4. Eg. If the overdrive distance = 500 mm (4 cage bar with 125 mm

The Overdrive Ratio = (Total Dist Travel by Cage/ Dist Travel by

1.2.4 What is “Spiral Belt Collapse”?

1. POULTRY INDUSTRY - chicken parts, chicken patties, chicken nuggets,

2. RED MEAT INDUSTRY - meat patties, meatballs, raw hamburger,

4. BAKERY PRODUCTS - pizzas, pies, cookies, pasta, bread dough.

5. PREPARED FOODS - packaged food in trays, shrimps in trays, ice cream

1.4 Spiral Freezer Terminology

Belt Stretch: Elongation of the belt due to physical wearing, not

Collapse Factor: A varying factor applied to the belts being used in a

Discharge: The point where the product leaves the spiral.

Drum: The central drum or tower which is usually a caged

Drum Drive: A motor and gearbox assembly directly driving the

Frame Assembly: The structural frame work which everything else in

Grid Belting: Metal belting with specific characteristic of strength,

Infeed: The point where the product enters the spiral

Lubrication: Required for drive assembly, selected drive chains,

Maximum Product Height: Dimensional number that should not be exceeded

Mobius Flip: Term applied to a method of continuous turning the

Overdrive: The additional distance, as the surface of the drum

Return: Layout of path of belt from the exit roller to the

Spiral: Description of belt pattern, more correctly described

Supports: Generally describing the structure supporting the

Tier: A 360 degrees element of the spiral either ascending

Tier pitch: Vertical distance between tiers.

Updrum/Downdrum: Describing systems with either ascending or

2.1 Drum Drive

2.2.1 Take-up Drive

The take-up drive is established through a separate horizontally mounted

2.2.3 Belt Fault Switches

Further protection to the system is provided by a proximity switch mounted

3.1 Start-Up Sequence

Normally, adjustments to the system should not be necessary.

It is important that once a spiral freezer has been pulled down to a

The machine must not be allowed to partially defrost.

3.2 Fault and Warning

3.3 Spiral Hygiene and Cleaning

Allowing contamination of parts and surfaces to persist will result in a

4. Maintenance and Trouble Shooting

2. Check Chain Tension