JAC V01-06-2019 Electric Automatic Vertical Dough Moulder Instruction Manual

JAC V01-06-2019 Electric Automatic Vertical Dough Moulder

Product Information

Technical Specifications

• Min/max weight of dough pieces in grams: UNIC: 0.75, TRADI: 50/1200, FORMA: N/A
• Maximum production rate in pieces per hour: UNIC: N/A, TRADI: 1800, FORMA: N/A
• Motor power rating (kW): UNIC: 0.75, TRADI: 0.75 Three-phase, FORMA: 0.75 + 0.37
• Motor type: UNIC: no, TRADI: yes, FORMA: yes
• Variable speed drive: UNIC: no, TRADI: no, FORMA: yes
• Flat bread outfeed: UNIC: N/A, TRADI: N/A, FORMA: yes
• Height x Width x Depth: UNIC: N/A, TRADI: N/A, FORMA: 240
• Net weight (kg): UNIC: N/A, TRADI: N/A, FORMA: 210

Product Usage Instructions

Before Commissioning|
Thank you for choosing a JAC system. Follow these steps before installing and commissioning the machine:

• Read the instructions carefully.
• Enlist the help of your approved agent for installation, commissioning, and service support.
• Ensure the service booklet is filled by your dealer during installation for the 5-year warranty.

Warranty

All JAC products are covered by a 5-year warranty. Remember:

• The warranty covers all parts excluding consumables and starts
  on the installation date.

• If not serviced by an approved agent or service booklet not
  filled correctly, the warranty is limited to one year.

Warnings
Important warnings for safe usage:

• Keep user instructions with the machine.
• Do not let children use the machine.
• Disconnect mains supply before cleaning or maintenance.
• Handle the machine with necessary safety precautions due to its weight.

BEFORE COMMISSIONING

Thank you for choosing a JAC system. It is essential that you read these instructions before installing and commissioning this machine. This will protect you and avoid damaging your machine.
These instructions refer to various illustrations in order to make them easier to understand. These illustrations are at the end of the instructions. Please refer to them whenever you see the following symbols: (fig.X, n°Y).
To ensure that your machine gives you full satisfaction over the coming years, we invite you to familiarise yourself with the following advice:

• Enlist the help of your approved agent for installation, commissioning and service support.
• In order to be covered by the 5-year warranty (see terms and conditions set out below), please have your dealer fill in the service booklet when your machine is being installed. The service booklet is at the back of your machine.

WARRANTY

All JAC products are covered by a 5-year warranty.

This warranty is valid for all parts on your machine, including electronic components but excluding consumables. The warranty takes effect on the date the equipment is installed.

Subject to the following restrictive conditions

• – Equipment acquired from an approved dealer;
• – Installation carried out by an approved agent;
• – Equipment used in accordance with the instructions for use and for the intended purpose for which it was manufactured;
• – Equipment serviced on a daily basis in compliance with the instructions for use;
• – Regular servicing by the approved agent in compliance with service specifications, with at least one service a year (servicing chargeable to the user).
• – Exclusive use of genuine JAC parts.

If there is no record of servicing by an approved agent and/or if the service booklet has not been filled in correctly, warranty cover will be limited to one year.

This warranty does not cover:

• – Replacement of consumables (§9);
• – Parts not accepted as defective by our company;
• – Problems due to improper use of the equipment;
• – Problems due to installation not carried out by an approved agent;
•  – Parts or problems due to transit damage or improper handling.

Repairing and/or replacing defective parts during the warranty period does not bring about an extension of said warranty.

WARNINGS

• It is most important that these user instructions be kept with the machine for any future reference. Should this machine be sold or transferred to another user, please ensure that the user instructions are handed over so that the new user can be familiarised with its operation and the warnings associated with it.
• These warnings are given for your safety and that of others. We would therefore ask you to read them carefully before installing and using the machine.
• This machine has been designed for use by authorised adults. Please therefore ensure that children do not touch it or use it as a toy.
• This machine is intended exclusively for professional use.
• It is dangerous to modify or attempt to modify the specifications of this machine.
• After having installed this machine, please ensure that it is not standing on the power cable. Follow the instructions given for its use.
• This machine must be stored and used in an indoor room, protected from moisture and heat.
• This machine must be adequately illuminated to operate it.
• The noise level of this machine does not exceed 75 dB(A) in accordance with EN ISO 3744.
• This machine must be used by one person at a time (unless otherwise specified).
• Always disconnect the mains supply before cleaning the machine inside/outside and when carrying out maintenance.
• This machine is heavy. Take all necessary safety precautions when handling it.

TECHNICAL SPECIFICATIONS

Min/max weight of dough pieces

in grams

| 50/1200
Maximum production rate in

pieces per hour

| 1800
Motor power rating (kW)| 0.75| 0.75| 0.75 + 0.37
Motor type| Three-phase
Variable speed drive| no| yes| no
Flat bread outfeed| no| no| yes
Height x Width x Depth| 708 x 962 x 760
Net weight (kg)| 210| 240
Pointed end belt| optional
---|---
Outfeed guides| optional
TRF20 outfeed belt| optional
TRF30 outfeed belt| optional
Standard wheeled base| optional
Wheeled base with storage| optional
Feed belt (Unic/Tradi)| optional
Variable speed drive (Forma)| optional

Details of materials in direct contact with dough.

• Chute: STAINLESS STEEL 304L.
• Roller: Food-grade white PETP
• Scraper blade: Lucoflex
• Front elongation belt: Wool/Synthetic Rear elongation belt: Wool/Synthetic Delivery belt: Wool
• Feed belt: ARCOT synthetic cloth.
• Forma outfeed belt: ARCOT synthetic cloth.

INSTALLATION AND COMMISSIONING

Unpacking the machine:
Machines are delivered from our works on pallets, strapped and protected with cardboard. First of all, the packaging must be examined and any damage caused in transit must be declared directly to the carrier.

1. Remove the cardboard.
2. Remove straps, taking particular care when they are released by cutting.
3. Detach the machine from the pallet (fig.17): Remove the left/right-hand doors using a flat-blade screwdriver, then loosen the tie rods screwed to the pallet with a 13 mm spanner.
4. Assemble the machine with its feet (for tabletop installation only).
5. For installation on a base, remove the right and left-hand doors in order to gain access to the feet, remove them and replace them with the screws provided with the base.

After unpacking your machine, check that it has not been damaged in transit. Notify us of any defects.

Positioning:
In order to achieve excellent performance and long-term reliability, choose a location that is: Well ventilated, shielded from direct sunlight and away from sources of heat, with a flat and sturdy surface free from vibration.

Electrical connection:
IMPORTANT: This machine must be earthed.
It is recommended that the system be protected with a fuse and an RCD.
Your mains electricity supply to the machine must be protected as indicated below:

• – North America: 15 A protection;
• – Rest of the world: 16 A protection.

For machines equipped with a variable speed drive, it is imperative that they be connected to a junction box on a circuit fitted with a 300 mA RCD.
Note: Any problem resulting from any other type of connection will not be covered under warranty.
Before connecting your machine to the mains supply and in order to prevent the motor from burning out when it is switched on, it is important to check that the mains supply matches the machine specification (see machine nameplate).
This machine complies with Machinery Directives 2006/42, 2006/95, 2004/108 and is CE marked as proof of this.
Please familiarise yourself with the safety pictograms displayed on the machine: This pictogram indicates an electrocution hazard. Please isolate the machine before carrying out any work on it. You will find it on the control panel, which acts as an electrical enclosure (fig.15, 16, n°28).
You will find the circuit diagram for the machine inside the electrical enclosure.

Commissioning
Before commissioning, ensure that there are no extraneous objects interfering with the machine’s moving parts. Ensure first of all (after verifying electrical compatibility) that the motor is rotating in the right direction. Do this by pressing the start button and checking that the front box belt goes upwards. If this is not the case, disconnect immediately and switch two phase wires in the plug. For machine operation, please refer to the “Operation” chapter.
Danger
If the user or the machine is in danger, you must use the main isolator switch to cut the power supply to the machine. Keep clear of the tray proofers when they are in motion. Remove the plug from the power socket before any maintenance and/or servicing work. Any maintenance work or replacement of parts must be carried out by an approved agent.

CONTROLS AND SAFETY FEATURES

Controls:
Your machine is equipped as standard with a mechanical control panel (fig.4, 5, 6). 6.2 Work area: The work area is located in front of the machine outfeed belt (fig.3, n°16).
Safety features:
This machine is equipped with the following safety features:

• – A lever switch (fig.14, n°26) if the safety chute (UNIC – TRADI) (fig.1, n°3) is pulled forwards or if the safety bar is operated (FORMA) (fig.2, n°14).
• – An encoded magnetic switch (fig.14, n°27) which prevents the machine from starting if the front housing is open.
• – An emergency stop button (fig.4, 5, 6, n°19).

Trigger action and mechanical latching emergency stop. Compliant with EN/IEC 60204-1 and EN/ISO 13850:2006, Machinery Directive 98/37/CE and EN/IEC 60947-5-5.

OPERATION

Pre-settings
The table below provides recommended settings. However, the nature of the dough and the moulding to be obtained must be taken into account. Trial and error is therefore often necessary and it is essential to take into account the relationships between each of the settings. For instance, insufficient rolling or elongation which is too tight results in an unattractive dough piece. Rolling is performed with the lower lever and elongation with the upper lever (pinch the handles to release, then raise or lower to achieve the desired setting).

Pancakes are rolled using the lower lever only.

NOTE
In order for the dough to be moulded and elongated properly, it is essential to flour

• – The box belt.
• – The elongation belt.

UNIC (fig.11)

1. Twist the mushroom (emergency stop) button (fig.4, n°19) ¼ turn to the right if it has not been released.
2. Press the START button (fig.4, n°20) to start the machine.
3. Feed the dough piece into the safety chute.
4. Collect the moulded dough piece on the delivery belt.
5. Press the mushroom button (emergency stop) (fig.4, n°19) to stop the machine.

TRADI (fig.12)

1. Twist the mushroom (emergency stop) button (fig.5, n°19) ¼ turn to the right if it has not been released.
2. Press the START button (fig.5, n°20) to start the machine.
3. Turn the potentiometer to set the desired speed (fig.5, n°22).
4. Feed the dough piece into the safety chute.
5. Collect the moulded dough piece on the delivery belt.
6. Press the mushroom button (emergency stop) (fig.4, n°19) to stop the machine.

FORMA (fig.13)

For operation in standard mode, refer to Unic operation (fig.11)

1. Twist the mushroom (emergency stop) button (fig.4, n°19) ¼ turn to the right if it has not been released.
2. Press the START button (fig.4, n°20) to start the machine.
3. Feed the dough piece into the safety chute.
4. Collect the moulded dough piece on the delivery belt.
5. Press the mushroom button (emergency stop) (fig.4, n°19) to stop the machine.

TRADI (fig.12)

1. Twist the mushroom (emergency stop) button (fig.5, n°19) ¼ turn to the right if it has not been released.
2. Press the START button (fig.5, n°20) to start the machine.
3. Turn the potentiometer to set the desired speed (fig.5, n°22).
4. Feed the dough piece into the safety chute.
5. Collect the moulded dough piece on the delivery belt.
6. Press the mushroom button (emergency stop) (fig.4, n°19) to stop the machine.

FORMA (fig.13)
For operation in standard mode, refer to Unic operation (fig.11)

1. To use the machine in “flat bread” mode, lift the hook to the right of the cover (fig.2, n°12).
2. Tip the flat bread belt (fig.2, n°13) over towards the front, right down.
3. Press the START button again (fig.6, n°20).
4. Feed the dough piece into the safety chute.
5. Collect the moulded dough piece on the delivery belt.
6. Once the “flat breads” are finished, press the mushroom button (emergency stop) (fig.6, n°19, A), to stop, then return the belt to the raised position.

If your FORMA is equipped with an optional variable speed drive (fig.6, n°22, B), please refer to the operation steps for the TRADI.
For reasons of food hygiene, under no circumstances must dough or flour left on the top of the machine or outside it, be reused or reintroduced into the food chain.

MAINTENANCE

• It is essential to ensure on a regular basis that the belts are operating correctly by monitoring: IMPORTANT: Correct tension. Correct tracking.

• The required adjustments must be carried out as soon as a malfunction is observed.

• It is imperative that this monitoring be carried out during the first weeks of operation (belt bedding-in period).
  The tension nuts must never be tightened excessively, as this would make centring the belt difficult due to excessive elongation.

• If the belt rides over to the right, tighten the nut on the right-hand side or slacken the nut on the left-hand side.

Daily, by a trained operator.

• On finishing work, clean the machine in order to prevent flour from accumulating, which could be detrimental to its operation.
• Raise the heavy-duty belt assembly (fig.1, 2, n°2), if necessary, brush the felt, the front (fig.1, 2, n°1) and rear (fig.1, 2, n°11) box belts and the feed belt (optional) (do not use a metal dough cutter to do this).
• Open the elongation setting (fig.4, 5, 6, n°17) to its maximum extent in order to help the belts dry through air circulation.
• If there is excessive moisture, dismantle the entire heavy-duty belt and the felt.

Weekly, by a trained operator.
Remove and clean the roller scrapers as follows:  (This must be done with the power to the machine switched off)

1. Open the front cover (fig.7).
2. Separate the rollers (fig.7) to the maximum extent.
3. Unhook the left and right-hand springs, push the scraper (fig.8, n°23) to the left to release its pin.
4. Clean the blade (check that there are no dough residues left).
5. Refit the scraper by locating each end in its mount and taking care to position each spring in its stop groove.
6. Repeat the procedure on the second scraper (fig.9, n°24) (UNIC, TRADI, FORMA) and the third

Six-monthly, by an approved agent.

• Ensure that there is no abnormal noise when the machine is in operation. At the same time check the belt for correct centring and tension.
• Make the necessary adjustments as required.
• The machine must be shut down.
• Check chain condition and tension (lubricate if necessary).
• Check the Poly V belt for correct tension and re-tension it if necessary (FORMA).
• Ensure that the rolling and elongation setting levers are operating correctly.
• Check that the belt is still in good condition (it is easy to determine simply by touch when its thickness becomes critical).
• Check that the elongation belt is in good condition.

CONSUMABLES

When ordering spare parts, check with your approved agent which part is required based on the spare parts catalogue issued by the manufacturer. Always quote the machine serial number shown on the nameplate. Your agent will place the orders with JAC.

List of CONSUMABLES

MALFUNCTIONS

WARNING: The machine must be isolated from the power supply before attempting any work on it.

The machine will not start

|

Check the main power supply and the power supply to the motor.

Check safety features (emergency stop button, chute safety cut-out, front cover safety cut-out).

Check protective cover safety cut-out (feed belt option).

The motor is humming but will not start

|

Check that a phase is not missing in the electric circuit. Check the power supply to the motor.

Products emerging from elongation are torn and unattractive.

|

Check belt tension.

Check scrapers for appearance and cleanliness. Check that there is no dough crust on the belts. Check felt for cleanliness (pointed ends option). Check elongation and rolling settings.

LIST OF COMPONENTS IN ILLUSTRATIONS

__

__

__

__

__

1,2

| 1| Front box
2| Heavy-duty belt assembly
3| Secure infeed chute
4| Loading area
5| Roller
6| Note taking area
7| Front cover
8| Delivery belt
9| Delivery table
10| Front cover opening handle
11| Rear box
__

2

| 12| Flat bread belt opening catch
13| Flat bread belt
14| Infeed chute
15| Safety bar
3| 16| Work area
__

4,5,6

| 17| Elongation setting lever
18| Roller setting lever
19| Emergency stop button
20| Start button
5,6| 21| Stop button
22| Speed setting button
8| 23| Scraper
9| 24| Scraper
10| 25| Scraper
14| 26| Lever switch
27| Encoded magnetic switch
15,16| 28| Pictogram indicating an electrocution hazard
29| Electrical enclosure

FAQ

Q: What should I do if my machine needs repair during the warranty period?
A: Contact an approved agent for repair or replacement of defective parts. Ensure all servicing is documented for warranty validity.

Q: Can children use this machine?
A: This machine is designed for use by authorized adults only. Keep children away from it to ensure safety.

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