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Piccolo_English_V07.

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Version 07, August 2010

Operating and Maintenance


Instructions for the
PICCOLO
Deck Oven

GmbH & Co.


Hans – Sachs – Straße 2 u. 3
D - 40721 Hilden
Tel.: +49 2103 490 40
Internet : www.wachtel.de
eMail : info@wachtel.de
Operating Instructions PICCOLO

1. Application---------------------------------------------------------------------------------------------------------------------------------- 4
2. Technical Data ---------------------------------------------------------------------------------------------------------------------------- 4
2.2 Water ----------------------------------------------------------------------------------------------------------------------------------------- 5
2.3 AquaQuell Purity - Data------------------------------------------------------------------------------------------------------------------ 5
2.4 Overflow ------------------------------------------------------------------------------------------------------------------------------------- 5
2.5 Exhaust air ---------------------------------------------------------------------------------------------------------------------------------- 6
2.6 Exhaust air system------------------------------------------------------------------------------------------------------------------------ 6
2.7 Electrical connection --------------------------------------------------------------------------------------------------------------------- 7
3. General notes------------------------------------------------------------------------------------------------------------------------------ 7
3.2 Steam application ------------------------------------------------------------------------------------------------------------------------- 8
3.3 Temperature -------------------------------------------------------------------------------------------------------------------------------- 9
3.4 Exhaust -------------------------------------------------------------------------------------------------------------------------------------- 9
3.5 Colour ---------------------------------------------------------------------------------------------------------------------------------------- 9
4. Operation ----------------------------------------------------------------------------------------------------------------------------------- 10
4.1 Operation of manual deck control----------------------------------------------------------------------------------------------------- 10
4.2 Operation of the DMS clock ------------------------------------------------------------------------------------------------------------ 12
4.2.1 Setting the time ------------------------------------------------------------------------------------------------------------------------ 13
4.2.2 Setting the start or night start time. ----------------------------------------------------------------------------------------------- 13
4.2.3 +/-keys.----------------------------------------------------------------------------------------------------------------------------------- 13
4.3 Operation of DMS – Master 100------------------------------------------------------------------------------------------------------- 14
4.3.1 On, off, night start --------------------------------------------------------------------------------------------------------------------- 14
4.3.2 The hood fan---------------------------------------------------------------------------------------------------------------------------- 15
4.3.3 Entering baking programs----------------------------------------------------------------------------------------------------------- 15
4.4 Operation with Master EM -------------------------------------------------------------------------------------------------------------- 17
4.4.1 Energy management by history---------------------------------------------------------------------------------------------------- 17
4.4.2 Energy management using the Eco-key ---------------------------------------------------------------------------------------- 17
4.4.3 Setting the current time -------------------------------------------------------------------------------------------------------------- 18
4.4.4 Energy management by means of readiness-for-baking time ------------------------------------------------------------- 18
4.4.5 Selecting readiness-for-baking time ---------------------------------------------------------------------------------------------- 18
4.4.6 Off and more---------------------------------------------------------------------------------------------------------------------------- 19
4.4.7 Entering and changing baking programs---------------------------------------------------------------------------------------- 19
4.4.8 Changing or entering names ------------------------------------------------------------------------------------------------------- 20
4.4.9 Changing or entering program parameters ------------------------------------------------------------------------------------- 20
4.4.10 Using the eco-key --------------------------------------------------------------------------------------------------------------------- 21
4.5 DMS 2 deck control ----------------------------------------------------------------------------------------------------------------------- 22
4.6 DMS 3 deck control ----------------------------------------------------------------------------------------------------------------------- 25
5. Design --------------------------------------------------------------------------------------------------------------------------------------- 28
6. Operation ----------------------------------------------------------------------------------------------------------------------------------- 29
6.1 First start-up -------------------------------------------------------------------------------------------------------------------------------- 30
6.2 Close down --------------------------------------------------------------------------------------------------------------------------------- 30
6.3 Start-up after a standstill ---------------------------------------------------------------------------------------------------------------- 31
7. Daily Operation ---------------------------------------------------------------------------------------------------------------------------- 31
7.1 Switching on -------------------------------------------------------------------------------------------------------------------------------- 31
7.2 Readiness for operation ----------------------------------------------------------------------------------------------------------------- 31
7.3 Charging ------------------------------------------------------------------------------------------------------------------------------------- 32
7.4 Baking ---------------------------------------------------------------------------------------------------------------------------------------- 32
7.5 End of baking time ------------------------------------------------------------------------------------------------------------------------ 32
7.6 Switching off -------------------------------------------------------------------------------------------------------------------------------- 32
8. The Proofing Cabinet -------------------------------------------------------------------------------------------------------------------- 33
8.1 Control --------------------------------------------------------------------------------------------------------------------------------------- 33
8.2 Function-------------------------------------------------------------------------------------------------------------------------------------- 33
8.3 The steam generator for the proofing chamber ----------------------------------------------------------------------------------- 34
9. Maintenance ------------------------------------------------------------------------------------------------------------------------------- 35
9.1 Safety precautions ------------------------------------------------------------------------------------------------------------------------ 35
9.2 Decalcifying the steam system -------------------------------------------------------------------------------------------------------- 35
9.3 Cleaning and replacing the lamps ---------------------------------------------------------------------------------------------------- 35
9.4 Removing and cleaning the door panes--------------------------------------------------------------------------------------------- 37
9.5 Cleaning the baking chamber ---------------------------------------------------------------------------------------------------------- 37
9.6 Cleaning the proofing cabinet ---------------------------------------------------------------------------------------------------------- 37
9.7 Cleaning the hood fan-------------------------------------------------------------------------------------------------------------------- 37
9.8 Cleaning the casing----------------------------------------------------------------------------------------------------------------------- 38
9.9 Avoid the following ------------------------------------------------------------------------------------------------------------------------ 38
10. Customer Service------------------------------------------------------------------------------------------------------------------------- 38
11. Faults and their causes ----------------------------------------------------------------------------------------------------------------- 39
11.1 . . . for Piccolo with analog control --------------------------------------------------------------------------------------------------- 39
11.2 . . . for Piccolo with DMS control------------------------------------------------------------------------------------------------------ 39
11.2 . . . .for the proofing cabinet ------------------------------------------------------------------------------------------------------------ 41
12. CE - Declaration of conformity -------------------------------------------------------------------------------------------------------- 42
13. GS - Prüfbescheinigung----------------------------------------------------------------------------------------------------------------- 44

Page 2 of 44
Operating Instructions PICCOLO

200

100 300

400
0 °C
JUMO

30
20 40

10 50
0 60
AUS
min JUMO

200

100 300

400
0 °C
JUMO

200
100 300

400
0 °C
JUMO

30
20 40

10 50
0 60
AUS
min JUMO

200

100 300

400
0 °C
JUMO

200
100 300

400
0 °C
JUMO

30
20 40

10 50
0 60
AUS
min JUMO

200 P
100 300

400
0 °C
JUMO

200

100 300

400
0 °C
JUMO

30
20 40

10 50

0 60
AUS
min JUMO

200
100 300
P
400
0 °C
JUMO

STOP

STOP

Piccolo with analogue control Piccolo with computer control


DMS2 with Master

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Operating Instructions PICCOLO

1. Application
The ovens of the PICCOLO series are designed for baking various goods and
are primarily used for instore bakery and pastry baking. The user is warned
against heating goods other than dough (foods) in the oven. Due to its modular
design the PICCOLO series can be extended. PICCOLO is offered in a number of
deck widths and depths. This oven is a production machine (technical working
appliance) not suitable for private use

Options:
- Hood equipped with a fan
- Lower-level proofing cabinet with temperature regulation and moisture dosage

2. Technical Data
Baking chamber Weight Width Depth Height Baking Output Output Output
in kg in mm in mm in mm area deck steam total
Mini-Piccolo EK H 120 975 840 335 0.24m² 2.2kW 1.2kW 3.9kW
Mini-Piccolo DK N 180 975 840 485 0.48m² 4.4kW 2.4kW 7.8kW
Piccolo I EK H 150 975 1240 335 0.48m² 4.1kW 1.2kW 5.3kW
Piccolo I DK N 260 975 1240 485 0.96m² 8.2kW 2.4kW 10.6kW
Piccolo II EK H 200 1560 1240 335 0.96m² 8.0kW 2.2kW 10.2kW
Piccolo II EK N 195 1560 1240 255 0.96m² 8.0kW 2.2kW 10.2kW
EK = single chamber, DK = dual chamber, H = high chamber (220 mm) N = low chamber (140 mm).

Proofing cabinet Weight Width Depth Height Baking Output Output Output
in kg in mm in mm in mm area deck steam total
Mini-Piccolo 80 975 840 535 5 units 0.9 kW 0.75kW 1.7 kW
Piccolo I 120 975 840 535 5 units 0.9 kW 0.75kW 1.7 kW
Piccolo II 150 1560 1240 535 5 units 0.9 kW 0.75kW 1.7 kW
For all Piccolo ovens the noise level is less than 74dB.

2.1 Location
The oven must be set up in a way that it is out of children's reach. The oven must
be placed on a safe, level, non-tilting base. In the case of installation against walls
or integration into shop furniture, care must be taken that fuses in the oven (at the
control side) remain accessible. A clearance of at least one metre must be ensured
in front of the oven so that it can be pulled forwards for maintenance work. Escape
routes must not be restricted by the oven.

Page 4 of 44
Operating Instructions PICCOLO

2.2 Water
The water connection (3/4" male thread) must be made via a hose so that the oven
can be moved forwards for maintenance purposes. A pressure reducer reducing the
water pressure to a maximum of 1 bar flow pressure must be provided by the
customer. A water conditioning system (approx. 2.856 mval/l) prevents excessive
calcifying of the steam system and thus lowers maintenance costs. Depending on
the water hardness and steam quantity, the steam system must be decalcified in
periods from every three months to one year. Caution! The feed and discharge
hoses must not be buckled. Refer to the separate installation plan for the
connections! The connections may only be modified or extended by an authorised
expert! Many decalcifying systems demineralise the water. This makes the water
corrosive, which attacks the steam generator since the water becomes saturated
with minerals in the steam system. Brita system AquaQuell 2 or 3.

2.3 AquaQuell Purity - Data

Model Model
AquaQuell AquaQuell
Purity 600 Purity 1200
Output in l at 10°KH approx. 5,110 approx. 9,360
Device dimensions:
Height in mm 519 540
Diameter in mm 247 288
max. water temperature approx. 30°C approx. 30°C
max. pressure approx. 6 bar approx. 6 bar
Delivery of corresponding AquaQuell-Purity including installation fittings (hoses, stop
cock, sleeve nipple and display unit).
AguaQuell – tested food grade quality according to Fresenius. All water-carrying parts
are foodsafe and possess TÜV / GS test certificates.
Guaranteed function only in connection with controlled service. Device replacement
depending on operation output, but necessary at least once a year. Replacement may
only be carried out by an authorised BRITA expert dealer. Please note that water
conditioning systems and salt-based decalcifying can attack and destroy all metals if
not appropriately adjusted.

2.4 Overflow
The overflow of the steaming system must be led into a siphon. Plastic parts may
not be used for this purpose, because the overflow water may have a temperature
of 100 °C and steam may escape as well. Refer to the installation plan for the
connections! The connections may only be modified or extended by an authorised
expert!

Page 5 of 44
Operating Instructions PICCOLO

2.5 Exhaust air


Ovens which are provided with an exhaust hood (option) have a tube fan with a Ø Lof
150 mm. In the case of connection to an exhaust tube or exhaust system a drain
and slope (to this drainage) must be provided since a considerable condensate
volume must be reckoned with. (With a slight slope away from the fan).
The condensate drain must be checked weekly and cleaned as required.
Even without exhaust hood an exhaust air connection (for steam exhaust) is
required. The diameter in this case is 100 mm. Condensate must be expected even
in shorter tubes. The condensate must not enter the baking chamber. The tube
cross-section must not be reduced. Stainless steel ducts are ideal as exhaust
tubes. Flexible aluminium tubes are not well-suited for this application. The
calculation of an air-conditioning system including cooling is to be based on the
latent heat dissipation. The heat dissipation, however, largely depends on the
baking chamber temperature, the steam quantity, and the charging frequency. The
following data refer to a baking chamber temperature of 235°C, 15 seconds steam
application and 20 minutes baking time.
Number of decks Mini-Piccolo Piccolo I Piccolo II
single deck 240 W/h 380 W/h 650 W/h
double deck 480 W/h 720 W/h 1,120 W/h
triple deck 720 W/h 1,060 W/h 1,690 W/h
four decks 960 W/h 1,400 W/h 2,230 W/h
five decks 1,200 W/h 1,740 W/h 2,770 W/h
six decks 1,440 W/h 2,080 W/h 3,310 W/h
The exhaust steam may have a temperature of up to 180°C which must be taken
into account when guiding it into a ventilation system or chimney.
The exhaust connection must be made in such a way that the oven can be moved away
from the wall for service purposes and easily separated from the exhaust air (if
necessary, collars are to be used). When connecting the oven to an exhaust system
(exhaust fan) care must be taken that no vacuum forms in the baking chamber (if
necessary, a damper must be used). Refer to the installation plan for the connections!
The connections may only be modified or extended by an authorised expert!

2.6 Exhaust air system


An exhaust air system can be supplied as an accessory to Piccolo. 4
Pos. 1 = Exhaust air fan
Pos. 2 = Exhaust air hood 1
Pos. 3 = Reduction
Pos. 4 = Exhaust air outlet * 2 3
Pos. 5 = Suction for steam exhaust
Pos. 6 = Condensate drain 6
Pos. 7 = Connection for steam exhaust 5
*From these points the connected exhaust air tube may not be longer than 5 m. Longer
exhaust air systems require an additional tube fan to be installed at the end of the exhaust air
7
system.

Page 6 of 44
Operating Instructions PICCOLO

2.7 Electrical connection


The cable to the CEE socket or to the connecting socket must correspond to the
power consumption of the oven and the cable length. Remember that cables
leading through an area with an ambient temperature over 30°C may only be
utilised at 71% (VDE). All ovens require a 5-conductor cable connection (L1, L2, L3,
N, PE, 230/400V~50Hz), if necessary, the PE must be installed separately. Refer to
the technical data for the connected load; in individual cases the connected load
may differ from the technical data. Therefore, the type plate must be compared with
this data prior to connection. Each single or dual chamber has a separate supply
lead, thus one CEE socket or connection socket each must be provided.

If the oven is equipped with a lower-level proofing cabinet, then the latter has a
separate supply lead (phase, N, PE, 220V~50Hz) which must be connected to an
interchange-proof CEE plug. If the proofing cabinet is connected without plug care
must be taken not to interchange phase and neutral conductor.

Connection and modifications of electrical equipment may only be carried out


by an authorized expert.

In the event of danger


A master switch identified as such must be provided by the customer outside the
danger area for emergencies. This master switch must be freely accessible and cut
off the entire electrical equipment in case of danger.

Note!
Multideck ovens must be connected to a sub-distribution (if necessary, in the Ci
casing) where the supply leads can be fused individually. Thus, the possibility is
given of de-energizing all decks in the event of danger. Refer to the installation plan
for the connections! The connections may only be modified or extended by an
authorised expert!

3. General notes
Notes

The ovens of the -Piccolo series are ideal for shop baking purposes and
are extremely easy to operate. Nevertheless, you and your staff have to familiarise
yourselves with the operation of the oven. Read the operating instructions and the
following important points carefully (9.1, page 30) prior to the first start-up of the
oven:

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Operating Instructions PICCOLO

3.1 Safety instructions!


- Persons who have not been instructed in the use of the oven are not allowed
to operate it! The oven may only be operated by persons older than 14 years.
- Ovens damaged during transport or during later use may not be put into
operation. Take particular care of the door panes, lamp glasses, water and
electrical connections. Should a part be defective, contact your customer
service engineer.
- The ovens of the wachtel-Piccolo series are only suitable for baking bread
and pastries.
- Have repairs carried out by the customer service engineer or experts only
(electrics, gas/water, heating, ventilation).
- Do not fix any inflammable stickers or signs to the oven (fire hazard).
- Clean the door stop (bottom) at regular intervals. The door pane may break
when shut in the case of non-uniform load.
- All protective films must be removed prior to the first operation since these
otherwise constitute a fire hazard.
- In regular intervals (at least once a year) maintenance and check of protective
measures must be carried out.
When baking salt and pretzel goods, care must be taken to remove the salt
which has fallen under the deck plate at least once a month. Salt is corrosive
towards steel and stainless steel and simultaneously attracts water. The
baking chamber may be damaged at such points.

3.2 Steam application


The product and the steam application period are important factors for correct
steam application to the goods to be baked.
The following product faults may occur when there is a fault during steam
application:

a) Volume to small (not enough steam)

b) Poor splitting (not enough steam)

c) No gloss (not enough steam)

d) Goods stick to the baking trays (too much steam)


although these have been
greased.

e) Volume normal, but no (a skin formed on the dough)


gloss.

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Operating Instructions PICCOLO

3.3 Temperature
It is important to rapidly empty the baking chamber immediately at the end of
the baking period so that the temperature does not decrease too much. It is
even more important to charge the oven quickly so that no skin forms on the
dough first put into the oven due to the high temperature in the baking
chamber. Once a skin has formed on the dough it does not absorb any steam.

a) The dough collapses (temperature too low)


after having risen well.

b) The dough shows a good (temperature too high or dough


colour and sufficient volume, entered oven while too cold)
but is still not baked through
inside.

c) Rolls lack crustiness and (temperature too low or exhaust


quickly turn sticky. insufficiently opened)

3.4 Exhaust
Whereas the exhaust is often opened shortly after steaming when baking
bread, the exhaust may only be opened in the last 2 to 3 minutes when baking
rolls and baguettes. A better result for baguettes is obtained by applying steam
5 - 10 seconds after closing the door of the baking chamber. Baguettes should
form a thin skin.

a) Rolls lack crustiness and (temperature too low or exhaust


quickly turn sticky. insufficiently opened)

b) Rolls have a poor and (exhaust opened directly after


irregular colour and rise too steaming)
high in the centre.

In order to function properly, the exhaust must be connected in a technically


correct manner. Check the function with the exhaust open. Steam or smoke
must escape rearwards and to the right.

3.5 Colour
Quality takes time. The baking time for rolls should never be less than 18
minutes and not more than 22 minutes. The dough is not properly baked
through inside if the baking time is too short and frequently an irregular
colour shows if the temperature has been set too high.
For ovens with the STIR S&Q system the baking time (according to the dough
weight) normally is between 12 and 15 minutes.

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Operating Instructions PICCOLO

4. Operation
4.1 Operation of manual deck control
Thermostat for upper
heat
200
150 250
100 300
50 350
400
0 °C
On/off switch for this
baking chamber

Baking timer with signal lamp. After


the baking time has elapsed an
acoustic signal is heard until the
30 pointer is set to OFF.
20 40

10 50
0 60
OFF On/off switch for steam heating.
Signal lamp is on when the steam
heating is switched on.

Thermostat for lower heat


200
150 250
100 300
50 350
400
0 °C
The steam key opens the solenoid valve
for the time of actuation. The signal lamp
in the key is on until the steam system is
ready for operation.

Page 10 of 44
Operating Instructions PICCOLO

① Temperature scale for setting the


200
1 baking temperature (upper heat).
150 250
Please mind that the temperature
100 300
regulation cannot be as exactly as a
50 350 2 digital control. Set the roll temperature
400 7
0 °C first to approx. 210 - 220°C.

3 ② Optical display of the actual


temperature is shown by the red drag
indicator.
③ The setpoint adjuster in the middle is
used to set the temperature for the
4
30 5 upper heat.
20 40 ④ Time scale for setting the baking time.
Once the set baking time has elapsed
10 50 8 the control lamp ⑤ is on.
0 60 ⑤ This optical display signals that the set
OFF baking time has elapsed. In addition,
6 an acoustic signal is heard.
⑥ This setpoint adjuster is used to set
the baking time. Once the baking time
10 has elapsed the pointer is positioned
200 on 0. In order to switch off the acoustic
150 250
100 300 signal the pointer must be set to OFF.
50 350 11 9
400
0 °C
12
⑦ The pressure switch above is used to switch the deck with deck illumination on
and off. The control lamp in the switch is on, when the deck is switched on.
⑧ The central pressure switch is used to switch on the steam heating which is
controlled automatically via a thermostat. The control lamp in the switch is on,
when the switch is on.
⑨ The pressure key in the centre opens the solenoid valve for the period of actuation
supplying the steam system with water. The control lamp in the key is on until the
steam generator has reached the set temperature, and signals, that the steam
generator is ready for operation if the key is not on. Do not press for more than 4
seconds!
⑩ This setpoint adjuster in the centre is used to set the temperature for the lower
heat.
⑪ Optical display of the actual temperature is shown by the red drag indicator.
⑫ Temperature scale for exactly setting the baking temperature (lower heat).
Steam exhaust is actuated via a rod system with the handle being located on that
side of the oven where the handle for the deck door is also located.

Page 11 of 44
Operating Instructions PICCOLO

4.2 Operation of the DMS clock


(Only for DMS 2)
The DMS clock contains the timer with display, the On key, the Off key, the night start
key, the fan switch and the adjustment keys (+ -).
① 7 Light emitting diodes. These
LED's indicate the weekday.
1=Monday, 2=Tuesday,
3=Wednesday, etc.
② Digital time display. This display
shows the time and the night start
time (refer to Pos. 5).
③ On key. This key is used to switch on
all decks.
④ Time key. The current time or start or
night start time can be set by pressing
this key (2 start times are possible).
⑤ Off key. This key is used to switch off
all decks.
⑥ Night start key. This key is used to
switch off the oven, if it is to
automatically restart at the previously
set start or night start time.

⑥ The start time and the start day briefly flash on the display when the oven is
switched off. When the oven switches on automatically, the night start key flashes
until the On key (Pos.3) is pressed (take over oven control). If the key is not
pressed within the next two hours, the oven switches off again and restarts at the
next night start time (automatic function for public holidays).
⑦ Hood fan 0. This key is used to switch off the hood fan.

⑧ Hood fan 1. This key is used to switch on the hood fan (stage 1, slow speed).
⑨ Hood fan 2. This key is used to switch on the hood fan (stage 2, full speed).
⑩ -key. This key is used to reset the time as well as the first and second night start
times.
⑪ +key. This key is used to advance the time as well as the first and second night
start times.

Page 12 of 44
Operating Instructions PICCOLO

4.2.1 Setting the time


Press and hold the time key ④until the display no longer flashes. If the time key is
released the display starts to flash. Then the time can be set using the +/-keys.
Subsequently, the day is set and displayed ① by briefly pressing the time key.

4.2.2 Setting the start or night start time.


Briefly press the time key ④ until the upper dot between the hour and minute display
flashes (--:--). Then set the day tipping the time key ④. Since there are two start times
for each day, the upper LED of the colon lights up for the first start time and the lower
LED of the colon for the second start time. Therefore, the time key must be pressed
several times until the required day appears. Then the start time can be set using the
+/-keys ⑩ and ⑪.

4.2.3 +/-keys.
If kept pressed the tens digits run slowly. Individual steps are performed by pressing
singly.

Page 13 of 44
Operating Instructions PICCOLO

4.3 Operation of DMS – Master 100


The DMS–Master is the alternative to the DMS clock (4.2), it contains the night start
function, the on and off keys, the hood
fan keys and the baking program
memory. All baking programs are entered
at the DMS Master. The DMS Master is
an option, it can save 11 baking programs
if a DMS 3 is connected and 99 baking
programs if a DMS 2 is connected. One
manual program (No. 0) is saved in the
respective DMS deck control. Additional
baking programs, graphic displays, core
temperature measurements, operational
data acquisition and power limitation are
possible by connection to our DMS
WinServer PC.

① One step back. Press this key to go one step back if you wish to change your
entry (programming times, program names, etc.).
② One step forwards. Press this key to proceed to the next step, e.g. if you do not
wish to change your entry when changing baking programs, and when changing
times, program names, etc.

4.3.1 On, off, night start


③ On key. This key switches the oven on.
④ Set clock and night start time
The oven must be switched on to be adjusted. To adjust the night start time simply
press the clock key briefly (Pos. 4). Two start times can be set for every day of the
week. The oven is always switched off manually. If the clock key is kept pressed
for longer than 5 seconds you can set the current time and date. The value which
can be adjusted flashes and can be set with the + or -keys. Move to the next or
previous value with the keys < and >. The value is saved by pressing the clock key
again.
⑤ Off key. This key is used to switch off the oven, if it is not to automatically restart
at the previously set start or night start time.
⑥ Night start key. This key is used to switch off the oven, if it is to automatically
restart at the previously set start or night start time. The start time and the start day
briefly flash on the display when the oven is switched off. When the oven switches
on automatically, the night start key flashes until the On key (Pos.3) is pressed
(take over oven control). If the key is not pressed within the next two hours, the
oven switches off again and restarts at the next night start time (automatic function
for public holidays).

Page 14 of 44
Operating Instructions PICCOLO

4.3.2 The hood fan


⑦ Hood fan 0. This key is used to switch
off the hood fan.
⑧ Hood fan 1. This key is used to switch
on the hood fan (stage 1, slow speed).
⑨ Hood fan 2. This key is used to switch
on the hood fan (stage 2, full speed).
If a baking program with steam
application is started in one of the
decks or if a baking program has been
completed at a deck the hood fan is
switched on automatically. In Setup can
be set when and how fast the hood fan
shall rotate in certain situations, e.g.
during steaming when a baking program
is started or the exhaust opens.

⑩ -key. The -key is used to set the time, start times, temperature and time setpoint
values. If the key is kept pressed for longer than 3 seconds the tens digits are
adjusted.
⑪ +key. The +key is used to set the time, start times, temperature and time setpoint
values. If the key is kept pressed for longer than 3 seconds the tens digits are
adjusted.
⑫ P–key. Baking programs can be entered and changed after pressing the P-key.
⑬ The display shows the next night start time or "Off" when switched off. When
switched on it shows the time and date. The dialog text appears here when
entering baking programs.

4.3.3 Entering baking programs


The DMS Master is pre-programmed with baking programs in the factory. You can
easily change the baking programs if your goods to be baked require other
temperatures, baking times, etc. If the symbols in the program keys of the DMS oven
control are unsuitable for your purposes because you bake other goods, you can order
different symbols from your service centre or representative which can be made
according to your wishes. After pressing the P-key on your DMS Master, the display
"Select baking program" initially appears. The + or -keys are used to select the next or
Change baking previous program. Now press the > key, if you
programs wish to change the program or the < key if you
Select baking program: wish to change the name. If you press the > key
01. Rolls the display shown alongside appears. The
< Name Program > temperature setpoint value for the upper heat
1. Upper heat: 230 C o flashes and can be adjusted with + or -. Press the
> key at the end of adjustment to move to the
1. Lower heat: 215 oC
setpoint value for the lower heat.
1. Baking time: 20min
< back forwards >

Page 15 of 44
Operating Instructions PICCOLO

Adjust the lower heat in the same way or continue with the > key. If you discover that
you have entered an incorrect setpoint value you can go back with the < key to correct
your error.
A baking program consists of a maximum of 5 temperatures (upper and lower heat) and
the corresponding baking times. You do not have to set all temperatures if only one is
needed. If a number of temperatures have been entered, the deck for which the
st
corresponding baking program has been loaded initially heats up to the 1 temperature.
On expiry of the corresponding baking time for the 1 temperature, and if a 2nd
st

temperature (upper and lower heat) and 2nd baking time have been saved, the oven
then heats up to this on expiry of the 1st baking time.
The sum total of the set baking times is shown in the baking time display of the DMS
oven control. At the end of the last set baking time the baking time end signal is heard.
Input can be terminated at any time by pressing the P-key. The baking program is then
saved. The steam can be set after having entered the temperatures. A delay can be set
for baguettes and other goods to be baked which do not receive steam immediately. A
further steam break and a second steaming time can be set in the same way.
Do not set more than 8 seconds! Move to the next
Delay: 0000 s
parameter, the exhaust time, with the > key. The
1. Steaming: 005 s
closed-time initially flashes and you can set how
End and save P long the exhaust is to remain closed after the start
< back forwards > of the baking program with +/-.
1. Exhaust closed:
017min
1. Exhaust opened:
003min
End and save P
< back forwards >
Press the > key to move to the open-time. Enter the time for which the exhaust is to
remain open here. Press the > key again to move to the last setting, the second
exhaust time. You can terminate or abort programming at any time by pressing the P-
key. If you wish to change an existing baking program, proceed to the parameter you
wish to modify and then press the P-key after having changed the corresponding
parameter.

Page 16 of 44
Operating Instructions PICCOLO

4.4 Operation with Master EM


The keys that are needed are always displayed on the touch screen of the Master. On
the display shown here, these are (from left to right) the keys 0 (Off), hood fan, P
(programming) and eco.
1 12 Croissant Operation with the eco-function
2 04 Rolls When operating more than 6 decks, the upper 6 decks
are displayed first. The framed figure shows the deck
3 04 Rolls number (from top to bottom). Scrolling ( ) shows the
4 22 Baguette decks currently not displayed.
If a deck is not used for an adjustable time, it reduces
5 22 12:22 Ready for the temperature automatically. In front of the deck
baking number ( 3 ) the thermometer appears, with the arrow
6 00 Manual program pointing downwards.

P
When a baking time has been started in a deck, the symbol appears in front of the
deck number. The symbol always appears in front of the deck number when a break
time has been set using the eco-key during which the deck is not needed.

4.4.1 Energy management by history


The Master remembers how the oven is used and automatically reduces the
temperature if during the previous weeks, on similar days of the week, these decks
were not used but were however switched on. If baking is nevertheless to be performed
with one of these decks, the On-key (or the 1/0 key) must be pressed on the deck.
If nothing is done, the Master switches the heating of the decks which are in energy
saving mode or in the break on again in good time so that these decks have achieved
the correct temperature again before the next anticipated baking process.

4.4.2 Energy management using the Eco-key


After pressing the Eco-key , one deck or several
Select readiness for baking decks which are not needed until later can be selected.
in 030 min at 10:20 A time is set at which the deck(s) should be ready for
Select deck(s)
baking. The Master lowers then the temperature such
1 2 3 4 5 that the decks will be ready for baking at the set time.
One key for each deck appears (1 = first deck top).
When the corresponding deck key is pressed the key
is framed.

If the symbol (darker eco) precedes deck no. , this deck is in energy saving mode
and does not heat. If the symbol (light eco) precedes deck no. , this deck is in
energy saving mode and heats. The deck heats despite energy saving mode when the
temperature is too low prior to the set baking time. The deck heats despite energy
saving mode when upon switching on energy saving mode, the setpoint temperature
has not yet been reached and/or cannot be reached within the set time.

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Operating Instructions PICCOLO

4.4.3 Setting the current time


Once the oven is switched off and the P-key is pressed, Setting the current time:
the current time can be set. Using the central arrow keys
and , the cursor can be set to the current time or to Monday, 15.01.07 - 11:45
the date. The switch from standard time to winter time is
effected automatically. Time and calendar are buffered
by a battery which is only used in case of power failure
and therefore does not need to be exchanged until after 4
to 6 years at the earliest.
4.4.4 Energy management by means of readiness-for-baking time
If the key is pressed longer, the setting mask "Set night start times" appears. The time at
which the oven should be ready for baking is set. The Master checks the residual heat in
Set night start times : in the decks prior to switching on the heatings and
Tuesday 1. 01:15 2. -- : -- switches on the colder decks first, followed by the
Wednesday 1. -- : -- 2. -- : -- warmer decks. In this way, all decks are simultaneously
ready for baking, the oven does not bake with heat from
earlier baking processes and energy is saved at the
same time. Two readiness-for-baking times per day of
the week can be set. If a readiness-for-baking time is to
be deleted the time must be set to 23:59 p.m. and then
the +key pressed once. There will be no night start if
the corresponding display shows - - : - -.
This setting is located between 24:00 and 00:01 o'clock.

4.4.5 Selecting readiness-for-baking time


Monday 15.01 .07 09:25:45 If the oven is switched off, the first possible readiness-
Please select next night start: for-baking times are displayed. If readiness-for-baking
Tue 16.01 01:15 is to be postponed to a later time, the cursor must be
Wed 17.01 01:30 moved downwards using the key. The start time on
Thu 18.01 01:30 which the cursor is placed is executed. The oven can
be switched off using the key if it is not to
automatically switch on itself. The cursor can be moved
to another time using the and keys. The key is
used to confirm the selected time and date.

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Operating Instructions PICCOLO

4.4.6 Off and more


Monday 15.01.07 09:25:45 When the oven is switched off it can
- be switched over to night start,
- be switched on,
- P be switched to change the current time and night
BACKÖFEN KÄLTETECHNIK starts
Oven switched off
- switch on and off the light.

P When the oven is switched to night start or switched off


the display darkens (adjustable) after approx. 5 minutes
and the keys 0 (Off), 1 (On), P (setting the current time)
and light appear.

1 12 Croissant When the oven switches on automatically a crescent


appears for each deck which is to switch on later
2 04 Roll
because it contains more residual heat.
3 04 Roll
4 22 Baguette
5 22 12:22 ready for
baking

P
4.4.7 Entering and changing baking programs
Change baking program Programming
Select program When the oven is switched on and the P-key pressed
Granary rolls the screen on the left appears. A used program position
Triangular whole meal (to be changed) or an empty one can be selected from
rolls the list to enter a new baking program. The right arrow
Crusty rolls keys are used to move the cursor in the program list.
_ The keys are pressed when the program name is to
Rolls be entered. The keys are pressed to enter the
Soup rolls program parameters such as temperature, baking time,
etc. The key is used to copy a baking program to
COPY
another empty program site. This function helps to shift the programs or to facilitate
work, when a similar baking program is to be created.

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Operating Instructions PICCOLO

4.4.8 Changing or entering names


06 Croissant For the first character, the cursor is placed on the
upper-case letter M. The second letter proposed is the
lower-case M. A total of 14 characters can be used as
56789:; < = >_ABCDEFGHIJKLM a name. If a name already exists, the cursor is placed
on this character. The cursor can be moved within the
written name using the upper and keys. The
cursor can be moved within the letter sequence using
the lower and keys.

The letter sequence:


012356789:;<=>_AÄBCDEFGHIJKLMNOÖPQRSTUÜVWX
YZ_aäbcdefghijklmnoöpqrstuüvwxyzß0123456789:;<=
> _ A B etc. etc. This letter sequence is infinite. There is a blank between > and A and
between Z and a. The umlauts ä, ö and ü are positioned after the corresponding letters.
4.4.9 Changing or entering program parameters
Change baking program First the temperature and baking time entry is
06: Cr oissant 10 min. displayed. 5 temperatures for upper and lower heat and
Upper heat : 200 °C 5 associated baking times can be entered. These are
Lower heat : 200 °C designated as temperature phases. Using the and
Baking time :010 min. arrow keys the cursor is moved between the lines.
010 min.
The double arrow keys and are used to jump to
the next temperature phase. Pressing the OK key
saves the program. The entry is aborted using the
key. Parameters such as temperature and baking time
can be changed with the and keys.
Unit digits can be changed by keying. The tens digits can be changed by pressing and
holding down the or key. The next parameter appears if a temperature phase is
skipped or all 5 temperature phases are entered. After the temperature phases the
Change baking program steam quantity is set. The delay is only set when the
06: Cr oissant 60 min steam is not be applied immediately, but after a short
while instead, as for example with Baguettes. Two
Delay 000 sec steaming times and one steam break can be set.
1. Steam: 0.2 litre Normally, the open-time of the solenoid valve is set. In
Steam break 010 sec the case of ovens equipped with a flowmeter (option)
2. Steam 0.3 litre the steam quantity is set in decilitres.

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Operating Instructions PICCOLO

Change baking program Finally, the time for steam exhaust is set. The
06: Cr oissant 60 min electrically operated steam exhaust is an option. The
Exhaust closed 02 min. sum of the baking times from the temperature phases
Exhaust open 13 min. is indicated on top as a reference.
Exhaust closed 35 Min. Program entry can be quitted at any time by pressing
Exhaust open 10 Min. OK (change is saved) or (without saving).

4.4.10 Using the eco-key


After pressing the eco-key , the decks which are not needed until later can be selected.
A time is set at which the decks should be ready for baking again. The Master
subsequently lowers the temperature such that the decks will be ready for baking again at
the set time.
1 02 12:00 ready for baking If different readiness-for-baking times are to be set in
various decks, the time for each deck must be set
2 02 12:05 ready for baking
individually. The time scheduled for readiness for
3 04 Rolls baking is shown behind the program number. The
4 04 Rolls same symbol also appears when the deck temperature
is automatically decreased because the deck has not
5 01 12:10 ready for baking been used on similar days of the week.

0 P
Even in this case, the readiness-for-baking time is displayed. If the deck is to be used
however, all that is needed is to press any key on the deck.

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Operating Instructions PICCOLO

4.5 DMS 2 deck control


⑩ The -key is used to reset all setpoint values and times.
⑪ The +key is used to advance all setpoint values and times.
⑫ When the temperature key is
pressed the temperature display ⑬
changes from actual value to setpoint
value. The display and the LED in the
key flash. A new temperature value
can then be set using the +/-keys.
The adjustment can be continued as
long as the display flashes. The set
value is saved by pressing the
temperature key once again. The set
value is automatically saved approx.
5 seconds after the last change. Pos.
⑫ and ⑬ are presented in duplicate,
at the top for the upper heat and at
the bottom for the lower heat. If the
temperature in one deck (upper and
lower heat) is to be adjusted by the
same value (parallel adjustment),
both temperature keys must be
pressed one after another and
adjusted using the +/-keys. Both
setpoint values then change by the
same value.
⑬ The temperature display shows the
temperature of the upper and lower
heat during normal operation. The
setpoint value flashes on the display
during temperature adjustment.

⑭ The baking time can be set using the +/-keys when the baking time key is pressed.
The adjustment can be continued as long as the display flashes. The set value is
saved approx. 5 seconds after the last change. The baking time can be extended,
when the horn is switched off using the baking time key and the baking time
prolonged with the +key. This extension is not saved.

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Operating Instructions PICCOLO

⑮ The baking time display shows various times: the baking time if the start key , is
not pressed, the remaining baking time if the start key is pressed, the exhaust
open and closed time ⑯ and the steaming time (in sec.) when it is set.
⑯ The exhaust key opens and closes the steam exhaust. When a program is started
(baking time runs) the position of the exhaust (open or closed) can be changed
using this key. When no program or manual program has been started a closed-
time can be entered (the top display reads CLOSED) after pressing this key and
when pressed again one open-time can be entered (the word "OPEN" appears in
the upper heat display). When the start key has been pressed the exhaust remains
closed for the set time (in minutes) and opens then for the set open-time to close
afterwards. To open and close the exhaust in the case of a baking program which
⑯ has not been started the key must be
pressed for longer than 3 seconds.
The LED in the key comes on when
the exhaust is opened.
⑰ Every single deck of an oven can be
switched off with the deck key. The
key position is saved. This means
that after switching the oven on via
the DMS clock or DMS Master, only
those decks are switched on which
were on when the oven was last
switched off. The key thus functions
like a mechanical switch.
⑱ The P-key has two functions. It is
used to switch the deck light on and
off. If the oven is connected to a PC
or equipped with a Master (options),
the P-key is used to load programs. In
this case the deck light automatically
switches on when the oven is
switched on. The P-key functions like
a mechanical switch and its setting is
saved as in the case of the deck key
⑰.
⑲ The setting of the steam heating key
is also saved. The key is used to
switch on the steam heating.

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Operating Instructions PICCOLO

⑲ An LED in the top right-hand corner of the key indicates that the heating is
switched on. Another LED in the bottom left-hand corner lights up until the heating
has reached the preset temperature (LED off, steam generator ready).
The manual steam key is used to
⑳ open the solenoid valve for steam
generation. The solenoid valve
remains open as long as the key is
pressed (manual steam application is
possible at any time).
When the steaming time key is
pressed, the steaming time (in sec.) is
indicated on the baking time display
⑮. The time can be adjusted using
the +/-keys. Set a maximum of 8
seconds! The steaming time must be
set to 000 if steaming is not required
or if the steam is to be controlled
manually. The LED in the key
flashes when a steaming time has
been saved.
The following preset times run down
in parallel when the start/stop key is
pressed: baking time, steaming time,
exhaust-closed-time and then
exhaust-open-time. The start/stop key
is used to terminate the baking
program when the baking time end
signal is heard. A baking program can
be stopped when the start/stop key is
pressed prior to the end of the
program. If a baking program is to be
extended the start/stop key may not
be pressed. Instead of the start/stop
key the baking time key is pressed
and a new time set. If no time
is set the baking time end signal sounds after one minute.

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Operating Instructions PICCOLO

4.6 DMS 3 deck control


The -key is used to reset all setpoint values and times. If no set key (exhaust, steaming
⑩ time, temperature or baking time) is pressed, the program no. of the loaded baking
program is displayed after pressing the -key.
The +key is used to advance all setpoint values and times. If no set key (exhaust,
⑪ steaming time, temperature or baking time) is pressed, the program no. of the loaded
baking program is displayed after pressing the +key.
After pressing the temperature key the temperature display changes from actual value
⑫ to setpoint value. The display and the LED in the key flash. A new temperature value
can then be set using the +/-keys. The adjustment can be continued as long as the
display flashes. The set value is saved by pressing the temperature key once
again. The set value is saved automatically approx. 5 seconds after the last
change. Pos. and are presented in duplicate, at the top for the upper heat and
at the bottom for the lower heat. If the temperature in one deck (upper and lower
heat) is to be adjusted by the same value (parallel adjustment), both temperature
keys must be pressed one after another and adjusted using the +/-keys. Both
setpoint values then change by the same value.
⑫ If a baking program has been loaded in the
DMS deck control, the temperature setpoint
value set in the baking program becomes
valid after the program start. The setpoint
value can only be permanently adjusted in
the manual program. Permanent
temperature adjustment for baking
programs is only possible in the DMS
Master
⑬ The temperature display shows the
temperature of the upper and lower heat
during normal operation. The setpoint
value flashes during adjustment of the
temperature. The display also flashes if the
temperature is more than 10°C beyond the
pre-set temperature (can be set in Setup).
⑭ Ifbaking
the set baking time key is pressed the
time for a manual program or the
baking time for a started baking program
can be adjusted. This adjustment can only
be carried out once for baking programs.
The persisting adjustment of a baking
program is only possible in the DMS
Master. The adjustment can be continued
as long as the display flashes.
.

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Operating Instructions PICCOLO

⑭ The original value (if nothing has been changed) or the new value is saved approx.
5 seconds after the last change. The baking time can be extended, when the horn
is switched off using the baking time key and the baking time prolonged with the
+key. This extension is not saved
⑮ The baking time display shows various
times: the baking time, if the start key
has not been pressed, the remaining
baking time, if the start key has been
pressed (the last minute of a baking
program runs down in seconds [59 – 0]
and at the end of the baking time all
three zeros in the display flash. The
exhaust closed and open-time and the
steaming time (in sec.) are only shown
in the manual program and can only be
adjusted in the manual program. Only
one baking time can be set in the
manual program .
⑯ The exhaust key opens or closes the
steam exhaust when the baking
program is started. The LED in the key
comes on when the exhaust is open. If
the manual program has not been
started the exhaust closed-time can be
set the first time the exhaust key is
pressed (the upper heat display shows
"CLOSED" and the closed-time flashes
in the baking time display). If the
exhaust key is pressed again the word
"OPEN" appears in the upper heat
display and the exhaust open-time can
be set.
⑯ Only one open and closed-time can be set in the manual program. Baking
programs can only be altered at the DMS Master or PC.
⑰ Every single deck of an oven can be switched off with the deck key. The key
position is saved. This means that after switching the oven on via the DMS clock
or DMS Master, only those decks are switched on which were on when the oven
was last switched off. The key thus functions like a mechanical switch.
⑱ The deck lighting is switched on and off with the light key. The light key does not
function like a mechanical switch, the light is always off when the oven is switched
on. However, the light can still be switched on even if the corresponding deck is
switched off. The LED in the switch comes on when the light is switched on.

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Operating Instructions PICCOLO

⑲ Steam heating is switched on and off with the steam heating switch. The steam
heating switch does not function like a mechanical switch, the steam heating is
always switched on when the oven is switched on.

⑲ The upper LED in the switch comes on when steam heating is switched on. A
further LED in the lower left part of the key comes on until the heating has reached
the pre-set temperature (LED off means steam generator ready).
The manual steam key is used to open
⑳ the solenoid valve for steam generation.
The solenoid valve remains open as
long as the key is pressed (manual
steam application is possible at any
time). The LED in the key flashes when
the solenoid valve is opened.
When the steaming time key is pressed,
the steaming time (in sec.) is flashing
on the baking time display (Pos. 15).
The time can be adjusted using the +/-
keys. Set a maximum of 8 seconds! The
steaming time must be set to 000 if
steaming is not required or if the steam
is to be controlled manually. The LED in
the key flashes when a steaming
time has been saved.
The following pre-set times run down in
parallel when the start/stop key is
pressed: baking time, steaming time,
exhaust-closed-time and then exhaust-
open-time.
The corresponding baking program is
loaded from the DMS Master to the
DMS deck control after pressing the
program select key (only if is not
already loaded). The loaded program
number is shown when the manual key
(or the +/-key) is pressed.
The symbols on the keys can be printed according to your requirements. There are
numerous symbols which we can arrange as required.
Even baking programs with names and baking times etc. can be entered as
desired, so that you can start immediately as soon as your new wachtel oven is
connected.

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Operating Instructions PICCOLO

5. Design
In all models the oven front, side panels and steam hood are made of polished or
brushed stainless steel.

Heating
The goods to be baked are heated by heating bars which are located in the deck ceiling
and below the hot plate. The heating bars are dimensioned so that the oven can be
heated in 30 - 60 minutes. The temperature decreases when the door is opened and
goods are placed in the oven. Steam heating is interlocked in the PICCOLO oven
series, thus reducing the connected load. However, ex works the ovens are supplied in
a non-interlocked state.
The power output of the steam heating ensures that the steam generator is heated to
the preset temperature within 20 minutes.

Design and function of the steam system


Each deck has its own steaming system located behind the rear wall of the baking
chamber. It can be accessed from the operator side (control side). The steam generator
is flanged laterally and can be removed for cleaning or decalcifying if required.
Steam enters the baking chamber through openings in the rear of the baking chamber.
The water for the steam system is separately controlled via a solenoid valve located at
the rear left in the oven.
The thermostats for the steam generators are also mounted in the oven in the area of
the associated steam generator. The temperature can be adjusted between 50 and
300°C. However, the set temperature should not exceed 270°C. Ovens with DMS
control work with a steam sensor electrically controlling the temperature.
The steam system comprises a steam generator, heating, thermostatic (or electronic for
DMS controls) temperature controller, spray tube and solenoid valve.
The water pressure must be at least 4 bar, reduced to 1 bar flow pressure by a
pressure reducer provided by the customer. A 3/4" male thread connection is provided
for the water supply. A water shock absorber is recommended to ensure pressure
compensation during the steaming process.
The water is sprayed into the steam generator by means of a spray tube. The steam
generator and the spray tube must be decalcified at least once a year, depending on
the hardness of the water. We recommend the use of a Brita filter system which we
can supply if required. This will considerably cut maintenance costs.

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Operating Instructions PICCOLO

Special features
There is an opening in the rear right part of the baking chamber to extract the steam. It
is manually controlled via a slide rod (separately for each deck). Ovens with DMS
control can also be equipped with a motor-controlled steam exhaust. The drive for the
electrical steam exhaust is located at the rear of the operator side above the steam
generator.
A halogen lamp (35W-12VAC) is installed on the operator side of the oven for each
deck. The oven light can be switched on and off separately for each individual deck.
(Refer to the Chapter "Maintenance" for instructions on changing bulbs.)

The PICCOLO is not equipped with a steam hood as a standard feature. The scope of
supply for the hood comprises an axial fan (Ø 150 mm). It is advisable to consult a
ventilation specialist if the steam hood is to be connected to an existing exhaust air
system or to a high chimney or if the exhaust air duct is very long.

Safety features
All ovens are insulated with high-quality mineral wool thermal insulation of the
carcinogenic index class <40 between the baking chamber and outer panelling in order
to prevent heat losses. This means that there is no suspicion of carcinogenic effects.
The ovens are subjected to quality control and tested for electrical safety before
delivery. A copy of the test report is among the documents received with the oven.

6. Operation
Please read the complete Operating Instructions before
starting work.
Open door of baking chamber
Open the door lock at arm's length by pressing down the door lever. Use protective
gloves for this purpose. Open the door only to a small gap so that heat and steam
can escape. When the door is fully open it is held in place by springs.
Close door of baking chamber
The door lever is lifted and slowly moved upwards to close the door.
Take care that the lower door stop is clean and there are no foreign bodies
between door stop and door pane. The glass door may break if there are foreign
bodies in front of the door stop.

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Operating Instructions PICCOLO

6.1 First start-up


All connections must be properly fitted. The water pressure must be reduced to 1
bar flow pressure. The supply leads to the oven must be interruptible by a master
switch which must be identified as such. Check that all protective film has been
removed prior to switching the oven on. Do not switch the oven on until you have
verified the correct connection. First read these Operating Instructions thoroughly
and then switch on the oven and the steam system off. Press the steam key to open
the solenoid valve. Now you can check whether the overflow of the steaming
system functions correctly because water must now emerge from the overflow. Set
both temperature controllers (for upper and lower heat) to 50°C and the baking time
to 45 minutes. Open the windows and doors of the room where the oven is installed
as the oven may still exhale. When the signal "end of baking time" is heard increase
the temperature by 50°C and continue in this manner until the oven has been left 45
minutes at 250°C. After these 3 hours and 45 minutes the oven is burnt in. It is
necessary to adhere to this procedure since water is drained from the stone floors
and grease from the glass wool insulation during this time.
Any brown discoloration on the front of the oven should be wiped off immediately
with a cloth.
The steam generator should not be switched on during this procedure because it
may attain higher temperatures than the baking chamber heating and thus deform
the hot plates.
The steam generator should not be switched on until the oven has reached 250°C
in order to degrease the thermal insulation in that part too. Do not increase the
temperature faster since otherwise the hot plates may deform. The oven is not ready for
operation until the baking chamber and/or steam generator has reached its
temperature. After having reached the baking temperature first check the steam system
by pressing the steam key for approx. 3 sec. Observe the density of the exhaust air or
of the steam exhaust. Leave the oven for a further 20 minutes before baking the first
pieces of dough.
6.2 Close down
If the oven is not operated for any length of time, the following points must be
considered:
Wait for 20 minutes after the last baking process before you switch off the oven. Never
pull out the mains plug as long as the oven is switched on. Open the door of the baking
chamber and shut off the water supply. Finally, pull out the plug and/or interrupt the
supply lead to the oven with the master switch.

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Operating Instructions PICCOLO

6.3 Start-up after a standstill


If the oven has not been operated for any length of time, the following points must be
considered:
Firmly close the door of the baking chamber and open the water supply. Plug in the
mains plug and/or switch on the oven using the master switch. Switch on the decks and
press the steam key for approx. 15 sec. Since the steam generator is still cold no steam
can be produced, but you can check whether the overflow of the steaming system
functions correctly. The oven cannot be charged until the baking and steam generator
temperatures have been reached. After having reached the baking temperature, first
check the steam system by pressing the steam key for approx. 3 sec. Observe the
density of the exhaust air or of the steam exhaust. Leave the oven for further 20
minutes before baking the first pieces of dough.

7. Daily Operation

7.1 Switching on
Switch on the required deck and set both temperature controllers to the
desired baking temperature. Then switch on the steam generator. Leave the
oven for approx. 15 minutes before charging it for the first time after heating it
to the required baking temperature (upper or lower heat) for the first time. The
signal lamp (or LED) in the steam key must be extinguished in order to bake with
steam. The oven can then be charged continuously.

7.2 Readiness for operation


The deck has reached the temperature when the LED's, at the right above the
scale of the temperature controller are extinguished. When the oven is equipped
with a DMS control the temperature is shown in the display.
The steam heating has two controls. The LED in the steam heating switch lights
up when steam heating is switched on. T h e L E D i n t h e steam key lights up
until the steam heating reaches the set temperature and is ready for operation.
Ovens with DMS control have two LED's in the On/Off-key for the steam
system. The upper right LED lights up when the steam heating is
switched on. The lower left LED lights up until the set temperature is
reached. Briefly press the steam key in order to moisten the air in the
baking chamber before charging. The hot dry air simultaneously escapes from
the deck during the first steaming process.

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Operating Instructions PICCOLO

7.3 Charging
Open the deck door and fill the oven using setters, trays, charging paddles or
other means. Ensure that there are no baking goods and no trays in the first 5
cm behind the door, as this prevents the oven door from being closed. Close the
door and release the steam required for the goods to be baked using the steam
key.
When the oven is equipped with DMS control only the baking program
must be started.

7.4 Baking
The baking time must be set after closing the deck door. If the steam exhaust is
to be opened at the end of the baking time it is sensible to set the time until
opening at the baking time clock. The baking time end signal is heard when the
exhaust is to be opened. Now open the steam exhaust (right-hand, next to the
deck door) and then set the residual baking time with the baking time clock so
that the signal sounds at the end of the correct baking time.
In the case of a DMS oven the exhaust must only then be drawn when
the oven has no electrical steam exhaust. Without electrical steam
exhaust the procedure is the same as for manual control.

7.5 End of baking time


Set the baking time clock to [OFF] at the end of the baking time (horn signal).
The hood fan (if present) must now be switched on, then the deck door opened and the
goods removed from the oven using adequate aids. Caution, baked goods and oven
are hot; therefore protective gloves must always be worn.
In the case of the DMS oven the start/stop key must be pressed to terminate
the baking time. The baking time can be extended by pressing the baking time
key instead of the star/stop key.

7.6 Switching off


Do not switch the deck off using the Off-key after a baking process until the
steam heating is again ready for operation.
If the oven is equipped with a night start function the decks which are to be
switched on by the night start device may not be switched off previously.
Should individual decks not be automatically restarted by the night start
function these decks must be switched off using the 1/0-key.
The oven takes approx. 45 minutes to reach the baking temperature. The
heating is a little faster (225°C in approx. 30 minutes) if the oven was used on
the previous day and a little slower (225 °C in approx. 45 minutes) after the
weekend. The deck doors must be closed in order to avoid losing heat even
when the oven has been switched off.

Page 32 of 44
Operating Instructions PICCOLO

8. The Proofing Cabinet


8.1 Control
The lower-level proofing cabinet is an optional feature. The proofer below the oven
is equipped with an electronic control system for temperature adjustment and
dosage of the relative humidity. Number and size of the trays used depend on the
oven size. The proofer is automatically switched either on or off with the oven if the
latter is equipped with a DMS clock or DMS Master. The temperature of 32°C and
the relative air humidity of 80% will be set in the factory. In order to avoid
unintentional adjustment by the operating staff the setpoint adjusters are arranged
inside the oven in the middle of the rear wall.

8.2 Function
The air heating (encircling the fan) is located in
the rear of the proofing cabinet. The heating
temperature is thermostatically controlled. A
~ -
+~

steam generator providing the moisture is


14 13 installed behind the rear wall of the proofer. The
steam generator temperature is thermostatically
controlled. The moisture is controlled via a hygro-
4 thermostat (at the inside rear wall, above the
suction unit). The solenoid valve is throttled in the
factory (with the potentiometer Pos. 12) so that
5 the steam only enters in such small quantities
1 Sek.

that no significant temperature increase is to be


12
expected. Depending on water hardness the
6 steam generator must be cleaned or decalcified
10 Sek. -

respectively every 1 - 2 months. Please note the


7 advice in chapter “maintenance”. When switching
on the oven the lower-level proofer will be
switched on too (lead time*). After 30 minutes the
8
R15 proofer works in the economical mode,
11 2 3 temperature and humidity will slightly go down.
1
When dough batches are brought into the proofer
Ein-Aus-

Hygrostat
Temperatur-

Thermostat

in any case the start/stop key has to be pressed


thermostat
Wasser-

begrenzer
Westernbuchse

Signal
Taster

(Pos. 17) to activate the proofer again. The


vierpolige

proofing time can be adjusted persistently using


the +/-keys prior to the start. If the proofing time
18 is adjusted after the start the adjustment is only
valid for the present proofing process. After
expiry of the proofing time an acoustic signal
is heard. In order to get a receipt you have to
STOP
15 16 17 press the start/stop key (Pos. 17).
After that the proofer turns again into the economical mode. *The lead time is set
when the oven is switched on and the +key (16) and the start/stop key (17) are pressed
simultaneously at the timer. To save the value the start/stop key must be pressed
subsequently.

Page 33 of 44
Operating Instructions PICCOLO

① Connecting plug for proofing timer


② Connecting plug for water thermostat and
temperature limiter
~ -
+~

③ Connecting plug for hygrothermostat


④ Connecting plug for power supply
14
(230V ~ 50 – 60 Hz) L K N PE 13
1 = Constant phase (load)
2 = Control phase (ON/OFF)
4 3 = Neutral conductor
4 = PE (protective earth)
⑤ Connecting plug for circulation fan
5 1 = Phase
1 Sek.

2 = free
3 = Neutral conductor
12 4 = PE (protective earth)
6
10 Sek. -

⑥ Connecting plug for water heating


1 = Phase
7 2 = free
3 = Neutral conductor
8 4 = PE (protective earth)
R15
⑦ Connecting plug for air heating
11 2 3 1 = Phase
1
2 = free
Ein-Aus-

3 = Neutral conductor
Hygrostat
Temperatur-

Thermostat
thermostat
Wasser-

begrenzer
Westernbuchse

Signal
Taster

4 = PE (protective earth)
vierpolige

⑧ Connecting plug for solenoid valve


1 = Phase
2 = free
18 3 = Neutral conductor
4 = PE (protective earth)
⑨ LED Power on
STOP ⑩ Main fuse 6.3 A (maximum 10 A)
15 16 17 ⑪ Bridge R15 must be replaced by resistor, if
switch with LED is connected.
⑫ Potentiometer for solenoid valve, opening time, 1 – 10 sec.
⑬ Fuse for transformer 0.315 A (maximum 0.315 A)
⑭ Transformer
8.3 The steam generator for the proofing chamber
Fresh water supply
Steam outlet with screw joint
Cleaning plug with drain
Thermostat
Heating

Page 34 of 44
Operating Instructions PICCOLO

9. Maintenance
PICCOLO deck-type ovens are largely maintenance-free. The maintenance work
described below must be carried out by a qualified electrician in compliance with
the VDE regulations.

9.1 Safety precautions


Prior to starting any work on the oven, the following safety
precautions must be observed in the order listed:

1. Switch off the oven (never use the fuse disconnector under load for
this purpose!).
2. Disconnect the oven from the mains by means of the fuse
disconnector and ensure that it cannot be switched on again (if
necessary, remove the fuses and lock the disconnector).
3. Check the absence of electrical power (measured at the terminals).
4. Ground and short-circuit the terminals.
5. Cover any adjacent electrical equipment which has been exposed by
opening the disconnector, control cabinet, subdistribution or meter
boards.

9.2 Decalcifying the steam system


The steam generators in the oven must be decalcified at least once a year (or
more frequently, in the case of water hardnesses beyond approx. 4.28 mval/l),
depending on the hardness of water and the amount of steam generated.

Important!
The steam generator may also be damaged if using aggressive chemical
decalcifiers. The biological decalcifiers for coffee-makers may be used (but
observe the dosage instructions).
Approximately 2.5 litres of decalcifier are required per steam generator
(depending on the oven model). A Brita filter system is better than decalcifying
as it reduces the amount of detergent or chemical decalcifiers used and cuts
maintenance costs, reduces machine downtimes and the impact on the
environment. The door pane of the oven need not be cleaned so often since no
limescale precipitates inside.
If necessary, have the steam system be decalcified by our customer service
engineers.

9.3 Cleaning and replacing the lamps


The PICCOLO baking chamber is illuminated by a 12V / 35W/ 300°C halogen light
bulb. Proceed as follows when changing the bulb:

Page 35 of 44
Operating Instructions PICCOLO

Replacing a defective bulb


Switch off the oven and disconnect the power supply (observe the safety
precautions on the previous page). The decks are fused in a subdistribution box
or a meter cabinet provided by the customer.
A miniature circuit-breaker often trips or a fuse blows when
the incandescent filament in the bulb breaks. Allow the oven
to cool down (the lamp glass and the bulb are also hot, not
just the oven). Turn the glass ball to the left and pull it off.
Hold the halogen lamp with a dry cloth and press it down
slightly.

Then tilt it slightly forward and lift it.

Now the lamp holder can be pulled out. The new bulb is
wrapped and should not be touched directly (use a dry and clean
cloth). Pull out the defective bulb and put a new one into the
base.

Now insert the lamp holder into the holding openings with the
side provided with two holding lugs (bottom).

Grasp the bulb (with a cloth) between the thumb and index
finger and subsequently push the individual lug slightly
rearwards with the index finger. If you now carefully push the
bulb slightly upwards, it will remain in place by itself.
Clean glass ball and gasket ring and then reinsert them. The
gasket ring must be in perfect condition (replace if necessary);
otherwise the bulb will be defective again after a short while.

The deck lighting is installed in the baking chamber (side wall) on the operator side.
To increase service life the bulb is protected against moisture, steam and dust by a
glass ball with good sealing properties. If the light does not come on after
replacing the bulb check the microfuse on the rear of the DMS control unit. For
this purpose first disconnect the power supply (observe the safety rules on
previous page).

Page 36 of 44
Operating Instructions PICCOLO

9.4 Removing and cleaning the door panes


The door panes may only be cleaned when cold to prevent them from bursting.
Clean them with commercial acetic detergents. Great care must be taken when
using window-cleaning sprays, as many of these contain silicone which may adhere
to the glass pane and burn during baking. This makes the pane rapidly become
opaque and the baked goods may acquire an unwanted taste. In addition, this type
of cleanser does little to prevent pollution. In the case of the PICCOLO, the door of
the baking chamber consists of safety glass. Remove the knurled screws at the top
of the pane to clean the glass. Then open the deck door and hold the pane with one
hand in the upper part. To remove the pane, hold one side towards the interior of
the oven and turn it. The pane can then be cleaned and replaced in reverse order.
Use decalcifier to remove the scale deposit on the inside of the pane. Scale
deposit can be avoided or reduced using a Brita filter system.

9.5 Cleaning the baking chamber


The deck chamber of the oven is self-cleaning and need not be cleaned. The deck
plate on the bottom of the deck chamber should be brushed out in cold condition.
Any dough adhering to the walls and base can be removed using a spatula. Do not
use scouring powder for cleaning and avoid liquids since the deck plate may distort.

9.6 Cleaning the proofing cabinet


The lower-level proofing cabinet must be cleaned every week depending on the
operation time. Do not use scouring powder for cleaning. In any case read the
instructions before using a cleaning agent. Following the reaction time, wash off the
cleaning agent and the dirt with clean water. Note that some cleaning agents may
not be discharged into the sewers! Slightly soiled parts may be cleaned with suds.
Please contact our customer service engineer for this purpose.

9.7 Cleaning the hood fan


The hood fan can be cleaned without water using a bottle brush and blown out with
compressed air. Observe the safety notes on Page 30 (9.1).
The cleaning work should only be carried out by an electrician or by our customer
service engineer. Above all it must be ensured that the fan is fixed after
reinstallation in such a way that no condensate gathers in the casing!

Page 37 of 44
Operating Instructions PICCOLO

9.8 Cleaning the casing


The oven casing also becomes warm during normal baking operation. Although
there is no danger of injury the oven should not be cleaned whilst still warm.
The cleaning agents dissolved in the cleaning water evaporate too quickly and
leave ugly stripes. The oven casing can be cleaned with a slightly moist leather
cloth.

9.9 Avoid the following


Do not wash or spray off the oven with a hose. Do not use a steam jet to clean the
oven.
Never scrape the pane, control elements (knobs and switches) or film with a knife
spatula or other solid object.
Do not use any inflammable substances or substances containing solvent. Fire
hazard!
Do not stick any signs (advertising) or stickers on the oven. Do not heat oil, grease
or other inflammable matters in the oven.

10. Customer Service


Your customer service engineers (take your own notes)

Machine service
Company Telephone Name

Water damage
Company Telephone Name

Electrical faults
Company Telephone Name

Local oven engineer


Company Telephone Name

Wachtel customer service +49 2103 - 490440 Mr Riedel


Wachtel spare parts sales +49 2103 - 490465 Mr. Linowsky
Wachtel installation +49 2103 - 490443 Mr. Fernández
Wachtel design +49 2103 - 490494 Mr. Wilpert
Wachtel project planning +49 2103 - 490497 Mrs. Holjevac
Wachtel electrical engineering +49 2103 - 490415 Mr. Knabben

Page 38 of 44
Operating Instructions PICCOLO

11. Faults and their causes


11.1 . . . for Piccolo with analogue control
Important safety precautions!
All work must be carried out by a qualified person. The oven must be switched
off before starting any work and the master switch and/or fuse disconnector
must be disconnected (ensure that the oven cannot be switched on again
inadvertently! Check that it is disconnected from the power supply, grounded and
short-circuited.)
No function Check fuses.
No steam, the LED in the steam key Check miniature circuit-breaker. Press steam
lights up which means that the key and check whether steam generator drain
temperature is not yet reached. is free. If not, check whether drain hose is
buckled or whether a small or large amount of
water permanently drains (solenoid valve leaky).
No steam, the LED in the steam key Check water pressure and solenoid valve.
does not light up. Check steam heating key - switched on?
Deck temperature rises only slowly Check fuses.
and drops when oven is charged.
Colour of goods baked too light and
not uniform.
Oven light remains off. Replace bulb and gasket, if necessary.
Oven light does not function after bulb Have microfuse (5 x 20 0.63A) checked.
has been replaced.

11.2 . . . for Piccolo with DMS control


Important safety precautions!
All work must be carried out by a qualified person. The oven must be switched off
before starting any work and then the Emergency-OFF main switch and/or fuse
disconnector must be disconnected (ensure that the oven cannot be switched on again
inadvertently! Check that it is disconnected from the power supply, grounded and short-
circuited.)

Oven does not function but no fault Check fuses. Check microfuse at the power supply
message either. unit.
Oven switches off after being switched
Oven has not been taken over in manual
on via the timer. control after night start (read page 12, 4.2 and
page 14, 4.6). Press the On-key.
No steam, the lower LED in the steam Check miniature circuit-breaker. Press steam
heating key lights up. key and check whether steam generator drain
is free.
No steam, the lower LED in the steam Check water pressure and solenoid valve.
heating key does not light up. Check steam heating key - switched on?

Page 39 of 44
Operating Instructions PICCOLO

Deck temperature rises only slowly Check fuses.


and decreases when oven is charged.
Oven light remains off. Check microfuse on relay board (LED glows
following failure). Replace bulb.
Control disturbed and performs a reset. Then
this fault message appears. Cancel the fault
Fault message on display: message by pressing the start/stop key, the
On/Off key or the night start key. Then check
F03.
the baking program and switching time or clock.
Fault message on display: Compensating sensor in control defective. Call
F70. customer service engineer to replace control.
Temperature sensor for upper heat defective.
Fault message on display: Check and clean (contact spray) control plug.
F71. Call customer service engineer.
Temperature sensor for lower heat defective.
Fault message on display: Check and clean (contact spray) control plug.
F72. Call customer service engineer.
Temperature sensor for upper heat incorrect.
Check and clean (contact spray) control plug.
Fault message on display: Call customer service engineer.
F73
Temperature sensor for lower heat incorrect.
Check and clean (contact spray) control plug.
Fault message on display: Call customer service engineer.
F74
Control cabinet temperature on control panel
too high. Open control panel and check fan if
Fault message on display: necessary. Call customer service engineer.
F79
Watchdog in the control has detected a fault
and performs a reset. A customer service
Fault message on display: engineer must be called to remedy the cause of
the fault if this fault message appears
F90 to F 99
repeatedly. Note the fault number. Press the
start/stop key, On/Off key or night start key to
cancel the fault message. Then check the
baking program or switching time and clock.

Page 40 of 44
Operating Instructions PICCOLO

11.2 . . . .for the proofing cabinet


Fault message on display: Main fuse on the board defective. Check the
F20. microfuse ⑬ on the relay board (LED on
board does not light up following failure)
1. Check water pressure.
No humidity 2. Switch the oven on and off several times when
the proofing cabinet automatically switches on
with the oven; otherwise use On-key
3. Steam generator furred up?
No temperature 1. Temperature limiter switched off at the inner rear
panel (Klixon)?
2. Hygrothermostat defective?
3. Fuse blown?
Temperature too high Hygrothermostat defective or humid. If necessary,
remove and dry. (Caution: low voltage 5V)
Check voltage at the mains connection plug ,
No display (230V ~ 50 – 60 Hz) L K N PE
1 = Constant phase (load)
2 = Control phase for transformer (ON/OFF)
3 = Neutral conductor
4 = PE (protective earth)

Text and drawings by Uwe


Keßelhut.
Subject to technical changes.
These Operating Instructions
may only be duplicated with the
prior approval of the firm of
Wachtel.

Page 41 of 44
Operating Instructions PICCOLO

12. CE - Declaration of conformity


- Declaration of Conformity
in the intendment of the EC Guidelines 89/392/EEC,
Appendix II A

Firma Wachtel Bäckereimaschinen und Backöfen


D-40721 Hilden
Hans-Sachs-Straße 2-3

We hereby confirm that the product mentioned below

Deck-type oven Name of the machine / system


“PICCOLO” Type or make
Electric deck-type baking oven without (machine /system description )
recirculation air heating
for baking dough (foodstuffs) Information on normal use

complies with the following relevant provisions:

GS - NG - 2 (e.g. EC guideline "Machine" as


( Issue 01/93 ) amended by 91/368/EEC,
Appendix I, EC low-voltage
guideline (73/23/EEC))

Applied harmonized standards, in particular:

89/392/EEC
91/368/EEC
EN60204 / EN60335-1 / EN60335-2 / EN60335-6
IEC335-2-12

The technical committee on food and luxuries “Test and Certification Body” has
checked the aforementioned product of the "deck-type baking oven" series. A test
report has been filed under no. 95034 ( 612.17 Be/Ba 057.01 ).

Date : -------------------------------- Name :U. Keßelhut


Place: Hilden

Signature

Page 42 of 44
Operating Instructions PICCOLO

Appendix to the - declaration of conformity


“PICCOLO” series

We hereby confirm that the materials used by us and listed below are
physiologically harmless, are permissible for use in the foodstuffs sector, are
not harmful to humans and can be easily cleaned.

Description of the components in contact Material


with foodstuffs

Baking trays “Lavaton” artificial stone based


on silicate-clay
or or glass fibre reinforced
concrete with exclusively
inorganic components which are
harmless to health

Oven chamber ST1203 steel

We hereby declare responsibility that determination of the workplace-related


emission value according to Din 45636, part 1, sects. 3.17, 7.3 and part 29, sect.
5.4.4 was performed for the equipment for upcoming certification. It is less than 60
dB for the “PICCOLO” deck-type oven.

Page 43 of 44
Operating Instructions PICCOLO

13. GS - Prüfbescheinigung
D
Diig
giitta
alliissiie
errtte
eKKo
oppiie
e Fachausschuss
Nahrunds- und Genussmittel
Prüf- und Zertifizierungsstelle
im BG-PRÜFZERT

Hauptverband der gewerblichen


Berufsgenossenschaften
GS-Prüfbescheinigung 06045
Bescheinigungs-Nummer
Name und Anschrift des Wachtel GmbH & Co.
Bescheinigungsinhabers: Hans-Sachs-Straße 2-3
(Auftraggeber) D-40721 Hilden
Name und Anschrift des dto.
Hersteller:

Zeichen des Auftraggebers: Zeichen der Prüf- und Zertifizierungsstelle: Ausstellungsdatum:


612.17 10.04.2006
----------------------------------------------------------------
Produktschlüsselnummer: 009.4501

Produktbezeichnung: Etagenbacköfen

Typ: Piccolo I, Piccolo II


Mini Piccolo
Piccolo ECO I, Piccolo ECO II, Mini Piccolo ECO
Bestimmungsgemäße
Verwendung:

Prüfgrundlagen: GS-NG 2 Prüfgrundsätze für Nahrungsmittelmaschinen 10/99

Bemerkungen: Nachfolgebescheinigung zu derjenigen mit der Prüfnummer NG 01038.

Das geprüfte Baumuster stimmt mit den in § 4 Absatz 1 des Geräte- und Produktsicherheitsgesetzes genannten
Anforderungen überein.
Das Baumuster entspricht somit auch den einschlägigen Bestimmungen der Richtlinie 98/37/EG (Maschinen).
Der Bescheinigungsinhaber ist berechtigt, das umseitig abgebildete GS-Zeichen an den mit dem geprüften Baumuster
übereinstimmenden Produkten anzubringen. Der Bescheinigungsinhaber hat dabei die umseitig aufgeführten Bedingungen
zu beachten.
Diese Bescheinigung einschließlich der Berechtigung zur Anbringung des GS-Zeichens wird spätestens ungültig am:
25.05.2011
Weiteres über die Gültigkeit, eine Gültigkeitsverlängerung und andere Bedingungen regelt die Prüf- und
Zertifizierungsordnung vom April 2004.

...............................................
Unterschrift (Zertifizierer)
Postadresse: Hausadresse: Tel: (0621)4456-3430
Postfach 10 04 41 Dynamostraße 7-11 Fax: (0621)4456-3470
PZB03D
05.04 68136 Mannheim 68165 Mannheim

Page 44 of 44

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