Janssen F Series User manual

Operating Instructions, Janssen Cookie Former
F250 UL / F450 UL / F600 UL
(Translation of original operating instructions)
05_2020_US_CA

Niederrheinische Formenfabrik
Janssen GmbH has been manufactur-
ing high-quality and robust machines
since 1872. As with previous machine
generations, our main goal was to
base the design of the F-Series on the
suggestions, wishes and needs of our
customers collected over many years,
thus creating a product to meet the
requirements of the present and
future as they become more demand-
ing in so many respects.
We are proud and extremely happy
that the presentation of the highest
distinctions dealing with the most
prestigious international innovation
and design awards has confirmed our
work.
Janssen – Numerous international awards!

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"Congratulations on your
new Janssen cookie former.
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We wish you great
enjoyment & pleasure
with your new machine!"

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Niederrheinische Formenfabrik
Janssen GmbH
Moerser Strasse 33
47798 Krefeld
Phone [phone]
Fax [phone]
[e-mail]
www.nff-janssen.de

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"Please read carefully before use!
Keep for future reference!
These operating instructions are part of the machine."
– Your Janssen team –

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Contents
1 Information on these operating instructions
1.1 Purpose ...........................................................................10
1.2 To whom is this manual addressed? ...........................10
1.3 Information for the operator.........................................10
1.4 Further applicable documents.....................................10
1.5 Availability.......................................................................10
1.5.1 Storage .........................................................................10
1.5.2 Distribution ..................................................................11
1.6 Typographical conventions ...........................................11
2 Notes for the operator
2.1 Scope of delivery ............................................................12
2.2 Responsibilities..............................................................12
2.4 Instruction of the operating personnel.......................12
2.5 Liability............................................................................12
2.6 External interfaces........................................................13
2.7 Marking of the machine ...............................................13
2.8 Spare parts.....................................................................13
2.9 Service address..............................................................14
2.10 Service links for documentation ................................14
3 Product description
3.1 Product benefits and overview.....................................15
3.2 Machine overview ..........................................................16
3.3 Basic operating principle..............................................17
3.3.1 Forming cookies .........................................................18
3.3.2 Forming dough bands ................................................19
3.4 Product types in the process ...................................... 20

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3.5 Characteristics of the doughs......................................20
3.6 Design of the machine...................................................22
3.6.1 Mechanical design ......................................................22
3.6.1.1 Base frame/ roller holder.......................................24
3.6.1.2 Machine body............................................................24
3.6.1.3 Dough hopper...........................................................24
3.6.1.4 Pattern roller and kneading roller ........................24
3.6.1.5 Conveyor belt cartridge...........................................24
3.6.1.6 Knife...........................................................................25
3.6.1.7 Sheet transport ........................................................25
3.6.1.8 Dough box .................................................................26
3.6.1.9 Roller heating ...........................................................26
3.6.1.10 Crumb tray ..............................................................26
3.6.1.11 Sensors ....................................................................26
3.6.1.12 Gear unit housing ...................................................27
3.6.1.13 Switch housing........................................................27
3.6.1.14 Operating terminal.................................................27
3.6.1.15 Power cord holder..................................................27
3.6.2. Controller design.......................................................27
3.6.2.1 "Performance" controller with touch
display/ programmable.......................................................28
3.6.2.1.1 "Main menu" ..........................................................28
3.6.2.1.2 "Settings"...............................................................29
3.6.2.1.3 "Language" ...........................................................30
3.6.2.1.4 "Info" ..................................................................... 31
3.6.2.1.5 "Select programme" .......................................... 32
3.6.2.2 "Compact" controller, manually operated/ not
programmable..................................................................... 33
3.7 Drive scheme................................................................. 34
3.7.1 Drive scheme of the roller pair................................. 34
3.7.2 Drive of the upper conveyor belt .............................. 35
3.7.3 Sheet transport drive ................................................ 36
3.7.4 Knife drive ................................................................... 37
3.8 Functional and process-engineering
description ........................................................................... 37
4 Safety
4.1. Conventions for safety instructions........................... 38
4.2 Application range.......................................................... 38
4.3 Intended use .................................................................. 38
4.4 Use contrary to the intended purpose or
prohibited use...................................................................... 39
4.5 Tasks and qualifications of personnel ....................... 40
4.6 Safety-relevant information for certain life phases 42
4.7 Notes for the operator and on industrial safety ....... 43
4.8 Protective equipment and safety functions............... 43
4.8.1 Location and function of the main switch............... 43
4.8.2 Location and function of the
EMERGENCY STOP buttons............................................... 44

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4.8.3 Circuit breaker for protective grid ...........................45
4.8.4 Circuit breaker for conveyor belt cartridge ............45
4.8.5 Protective plate for the drive of the
conveyor belt cartridge .......................................................46
4.8.6 Protective plate for the knife blade..........................46
4.8.7 Protective cover for the gear unit and
switch housing......................................................................46
4.9 Location and meaning of symbols on the machine...47
4.10 Further information on the machine.........................47
4.11 Residual risks ...............................................................48
4.11.1 Sharp knife .................................................................48
4.11.2 High machine centre of gravity ...............................48
4.11.3 Closing range of the hopper ....................................49
4.11.4 Heavy machine components....................................49
5 Technical data
5.1 Data sheet .......................................................................50
5.2 Electrical circuit diagrams
"Compact" and "Performance".......................................... 51
5.3 Declarations of conformity for
materials used...................................................................... 51
6 Delivery, transport, unpacking
6.1 Qualifications of personnel .........................................54
6.2 Requirements and safety..............................................54
6.3 In-house transport ........................................................54
6.4 Off-site transport...........................................................54
6.4.1 Transportation restraint ............................................54
6.4.2 Example of transport securing of
an F250 on a pallet.............................................................. 55
6.4.3 Example of transport securing of
an F450 and F600 on a pallet ........................................... 56
6.5 Delivery .......................................................................... 57
6.6 Unpacking ...................................................................... 58
Important when accepting delivery of the goods! .......... 58
7 Installation conditions
7.1 Qualifications of personnel ........................................ 59
7.2 Requirements and safety ............................................. 59
7.3 Total space requirement .............................................. 59
7.4 Foundation and floor..................................................... 59
7.5 Dimensions and weights .............................................. 60
7.5.1 Dimensions/ Weight F250 ......................................... 60
7.5.2 Dimensions/ Weight F450......................................... 60
7.5.3 Dimensions/ Weight F600..........................................61
7.6 Ambient conditions ....................................................... 62
7.7 Supply connections ....................................................... 62
7.8 Customer supplied safety measures ......................... 63
7.9 Storage conditions ........................................................ 63
7.9.1 Storage of the machine.............................................. 63
7.9.2 Storage of the rollers................................................. 63
8 Initial commissioning/ start-up
8.1 Qualifications of personnel.......................................... 64
8.2 Requirements and safety ............................................ 64
8.3 Electrical installation................................................... 64

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8.4 Installation and initial start-up....................................65
8.5 Special tools, equipment, materials ...........................66
8.5.1. Special materials .......................................................66
8.5.2. Special equipment.....................................................66
8.5.3. Special tools for assembly and
maintenance .........................................................................66
8.5.4 Special tools for cleaning ..........................................67
9 Setting up/ equipping the machine
9.1 Qualifications of personnel ...........................................68
9.2 Requirements and safety ..............................................68
9.3 Releasing and locking the castors...............................68
9.4 Folding down the sheet transport unit........................68
9.4.1 Folding the sheet transport unit up..........................69
9.4.2 Folding the sheet transport unit down ....................69
9.5 Feeding and removing the baking sheets...................69
9.6 Adjusting the sheet guide..............................................70
9.7 Height adjustment of the sheet transport unit...........70
9.8 Removal and installation of the conveyor belt
cartridge................................................................................71
9.9 Adjusting the straight running of the upper
conveyor belt.........................................................................72
9.10 Removal/replacement of the upper conveyor belt ..73
9.11 Opening and closing the hopper .................................73
9.12 Installation and removal of the rollers......................74
9.13 Knife setting for the cookie thickness .......................76
9.14 Installation and removal of the knife .........................77
9.15 Adjusting the sheet sensors........................................77
9.16 Adjusting the dough sensor ....................................... 78
9.17 Adjusting the roller heating ....................................... 79
9.18 Installation and removal of the crumb drawer........ 79
9.19 Installation and removal of the dough box............... 80
9.20 Use of the roller holder.............................................. 80
9.21 Connecting and disconnecting the power supply ... 81
9.22 Operating the controller............................................. 81
10 Operation
10.1 Qualifications of personnel........................................ 82
10.2 Requirements and safety........................................... 82
10.3 Operating the machine............................................... 82
10.4 Operation of "Compact" controller; manual,
not programmable.............................................................. 84
10.4.1 Operating modes...................................................... 84
10.4.1.1 Permanent operation (continuous operation) ... 84
10.4.1.2 Automatic mode
(sensor operation)............................................................... 84
10.4.1.3 Sheet transportspeed ......................................... 86
10.4.1.4 Roller heating ....................................................... 86
10.4.1.5 Warning light ......................................................... 86
10.4.1.6 Further controls.................................................... 87
10.4.1.7 Restarting after an
EMERGENCY STOP ............................................................. 87
10.4.1.8 Restarting after a longer
standstill............................................................................... 87

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10.5 Operation/ "Performance" controller
with touch display/ programmable....................................88
10.5.1 Menu structure..........................................................89
10.5.2 "Main menu"..............................................................89
10.5.3 "Settings"...................................................................90
10.5.3.1 Operating modes....................................................90
10.5.3.2 "Info" pop-up window ...........................................93
10.5.3.3 Speed V1 of the entire machine ........................... 94
10.5.3.4 Speed V2 upper conveyor belt..............................95
10.5.3.5 Speed V3 sheet transport.....................................96
10.5.3.6 Knife frequency......................................................97
10.5.3.7 Roller heating.........................................................98
10.5.3.8 Biscuit length in mm (measured)........................99
10.5.3.9 Biscuit position relative to the front
edge of the sheet................................................................100
10.5.3.10 Factor for the spacing between
rows of cookies................................................................... 101
10.5.3.11 Number of rows of cookies...............................102
10.5.3.12 Rollers? ...............................................................103
10.5.4 "Language" .............................................................104
10.5.5. "Info"........................................................................105
10.5.6 Select programme.................................................. 110
10.5.7 Modifying a programme .........................................111
10.5.8 Create new programme using
"Select programme" and overwrite ................................ 114
10.5.9 Restarting after an emergency stop .................... 117
10.5.10 Restarting after a longer standstill.................... 117
11 Maintenance
11.1 Safety............................................................................118
11.1.2 Intervals/ maintenance schedule ........................118
11.1.3 Checking and testing the safety systems ............119
11.1.4 Inspecting the machine .........................................119
11.1.5 Required aids ..........................................................119
11.1.6 Required tools ........................................................119
11.2 Conveyor belt cartridge ........................................... 120
11.2.1. Removing and installing the conveyor belt
cartridge .............................................................................121
11.2.2 Changing the conveyor belts of the
conveyor belt cartridge .....................................................122
11.3 Sheet transport drive belts...................................... 130
11.3.1 Removal and installation of the sheet transport
drive belts........................................................................... 130
11.4 Sheet guide................................................................. 132
11.4.1 Installation and removal of the sheet guide ....... 132
11.5 Knife ............................................................................ 134
11.5.1 Removal and installation of the knife .................. 134
11.5.2 Fine adjustment of the knife perpendicular to the
discharge direction for consistent cutting thickness 138
11.5.3 Knife setting for the cookie thickness................. 139
11.5.3.1 Knife setting for cookie thickness/ basic setting
for blade shaft axial bearing block ................................ 140
11.6 Gear unit ..................................................................... 142
11.6.1 Lubrication of the gear unit................................... 143
11.7 Heater ......................................................................... 144
11.7.1 Removal and installation of the heater................ 144

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11.8 Controller ....................................................................147
11.8.1 In case of defects or faults.....................................148
11.8.2 Documenting maintenance....................................148
11.8.3 Space limits/
Safe installation/ Place of use ........................................148
11.8.4 Housing and seals...................................................148
11.8.5 Wiring and components .........................................149
11.8.6 Protective earth.......................................................149
12 Cleaning after shutdown
12.1 Qualifications of personnel.......................................150
12.2 Requirements and safety..........................................150
12.3 Required aids ............................................................. 151
12.4 Cleaning kit................................................................. 151
12.5 Cleaning steps............................................................152
12.6 Frequency of cleaning ...............................................152
12.7 Cleaning procedure ...................................................153
12.7.1 Cleaning the hopper................................................153
12.7.2 Cleaning the rollers ................................................153
12.7.3 Cleaning the knife ...................................................154
12.7.4 Cleaning the crumb tray.........................................155
12.7.5 Cleaning the conveyor belt cartridge ...................156
12.7.6 Cleaning the sheet transport.................................158
12.7.7 Cleaning the machine interior ...............................159
12.7.8 Cleaning the heater.................................................160
12.7.9 Cleaning the housing .............................................. 161
12.7.10 Cleaning the base frame ...................................... 161
12.7.11 Cleaning the operating terminal.......................... 161
13 Repairs
13.1 Qualifications of personnel ....................................162
13.2 Requirements and safety..........................................162
13.3 Required aids ..........................................................162
13.4 Required tools ..........................................................162
13.5 Repairing the machine .............................................162
14 Troubleshooting and fault rectification
14.1 Qualifications of personnel...................................... 163
14.2 Safety.......................................................................... 163
14.3.1 General information about dough preparation.. 164
14.4 Troubleshooting and fault rectification...................170
14.5 Sensor faults ..............................................................174
14.6 Conveyor belt faults...................................................175
14.7 Safety device faults....................................................176
15 Removing from service / Storage
15.1 Qualifications of personnel ....................................178
15.2 Requirements and safety..........................................178
15.3 Required aids ..........................................................178
15.4 Required tools ..........................................................179
15.5 Removing from service and storage of the
machine...............................................................................179
16 Dismantling and disposal
16.1 Qualifications of personnel...................................... 180
16.2 Requirements and safety......................................... 180
16.3 Required aids............................................................. 180

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16.4 Required tools ...........................................................180
16.5 Dismantling the machine..........................................181
16.5 Disposal of the machine............................................181
17 Declaration of Conformity�������������������������������������������182
18 Supplementary documents
18.1 Recipe book.................................................................183
18.2 Spare parts list ..........................................................183
18.3 Electrical circuit diagrams.......................................183
19 Quick start
19.1 Machine setup.............................................................185

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All rights reserved.
The reproduction of any contents of these operating
instructions, including in part, is only permitted with the
written permission of Niederrheinische Formenfabrik
Janssen.
Copyright ©
Niederrheinische Formenfabrik Janssen GmbH, 2020

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1.1 Purpose
This documentation contains impor-
tant information on the proper use and
safe operation of the cookie moulding
machine for the following life phases
of the machine:
• Delivery, in-house
transport, unpacking
• Connection conditions
• Storage conditions
• Installation conditions
• Assembly, installation and
initial commissioning
• Operation, use
• Cleaning/ decommissioning
• Inspection and maintenance
• Disassembly
• Disposal
1 Information on these operating instructions
1.2 To whom is this manual
addressed?
This manual is intended for:
• Operating personnel:
The operating personnel must have
been instructed on the machine and
have access to the manual.
• Specialist personnel:
The specialist personnel have
appropriate technical training which
enables them to correct faults and
carry out maintenance. Instructions
for maintenance can be requested
separately.
1.3 Information for the operator
Please pay special attention to the
safety-relevant sections!
You are also required to observe the
relevant country-specific accident
prevention regulations, safety
regulations and occupational health
rules.
1.4 Further applicable documents
In addition to these operating instruc-
tions, there are further instructions
for the quick start, repairs, spare
parts and similar.
1.5 Availability
The operating instructions are
provided on delivery in printed form
and, on request, also in digital form.
1.5.1 Storage
Please keep the operating instruc-
tions in a safe place and ensure that
they are always available at the place
of use. They must be read, understood
and observed by the user.

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1.5.2 Distribution
These operating instructions are part
of the cookie moulding machine.
Dealers, suppliers or resellers of our
cookie moulding machines are
required to ensure that the operating
instructions are delivered with the
machine and made available to the
customer!
1.6 Typographical conventions
For easy and quick comprehension,
various types of information in this
manual are supplemented by clear
illustrations and symbols.
1.6.1 Warnings
This warning sign indicates
hazards that must be
observed.
1.6.2 Signs for procedures
These information signs 1indicate
the sequence of procedures:
1.6.3 Signs for references
This symbol ( section 6) refers to
further sections and is supplemented
with the section number.

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2.1 Scope of delivery
The cookie moulding machines F250,
F450 and F600 are configured
according to the components and
pattern rollers agreed in the order.
The machine is therefore ready for
operation. Baking sheets are usually
not included in the scope of delivery.
These operating instructions are part
of the machine.
2.2 Responsibilities
Niederrheinische Formenfabrik
Janssen GmbH is responsible for
compliance with all relevant provisi-
ons of the machinery directive. See
the manufacturer’s EC Declaration of
Conformity in the annex.
Janssen cookie formers are intended
for professional use only.
The operator is responsible for the
intended use of the cookie moulding
machine and the avoidance of misuse.
2 Notes for the operator
2.3 Legal notice
These operating instructions are part
of the cookie moulding machine.
Dealers, suppliers or resellers of our
cookie moulding machines are
required to ensure that the operating
instructions are delivered with the
machine and made available to the
customer!
2.4 Instruction of the operating
personnel
The operator is obliged to ensure that
instruction is given in the safe
operation of the machine. Furthermo-
re, the operating instructions must be
accessible to the operating personnel
at all times.
Please keep the operating instructions
in a safe place and ensure that they
are always available at the place of
use. They must be read, understood
and observed by the operating person-
nel.
Only qualified personnel may:
• Perform maintenance and repairs
• Perform work on electrical
equipment
2.5 Liability
All information and notes in these
operating instructions have been
compiled in accordance with the
applicable standards and regulations.
Niederrheinische Formenfabrik
Janssen accepts no liability for
damage due to:
• Improper use
• Unauthorized modifications to
the machine
• Breakage and transport damage
• Disregard of the operating
instructions
• Use of untrained
personnel
• Use of spare parts not approved
by Niederrheinische
Formenfabrik Janssen

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2.6 External interfaces
The Janssen Cookie Formers of the
series F250,F450 and F600 require a
»20 Amp 3ØY 120/208Vac 4 Pole, 5
Wire Receptacle (Mennekes Part No.
ME 520R9W)« mains connection
soket.
JANSSEN cookie formers are
equipped with frequency converters.
Further important information on
connecting the machine can be found
in ( section "9. Initial commissioning/
Start-up, p. 64)
2.7 Marking of the machine
Each machine has an individual
machine number from which the
specifications and equipment of the
machine can be identified.
You will find the number on the type
plate and on the side panel of the gear
unit side of the machine (see following
figures).
Masch. Type: F250 C UL
208Y/120V 3PH+PE
50/60Hz
24V
MM.JJJJJJXXXX
Rated voltage:
Frequency:
Nominal power:
Nominal current:
Control voltage:
Masch.-No: YOM:
Niederrheinische Formenfabrik
Janssen GmbH
Moerser Str. 33-35
D 47798 - Krefeld
www.nff-janssen.de
No. on the
type plate
No. on the
side panel
2.8 Spare parts
For spare parts enquiries, please
quote the machine number and year of
manufacture.
Our spare parts list provides you with
a list of the most important spare
parts with photos and their designa-
tions.

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2.9 Service address
Niederrheinische Formenfabrik
Janssen GmbH
Moerser Strasse 33
47798 Krefeld
Phone [phone]
Fax [phone]
[e-mail]
www.nff-janssen.de
2.10 Service links for
documentation
You can also view the following
documentation online or download it
as a PDF.
Scan the following QR code with your
smartphone or enter the following
URL:
Link to the operating instructions:
www.nff-janssen.de/Info/user_manual
Link to recipes:
www.nff-janssen.de/Info/recipes
Link for maintenance:
www.nff-janssen.de/Info/maintenance
Link for cleaning:
www.nff-janssen.de/Info/cleaning
Link for spare parts list:
www.nff-janssen.de/Info/spareparts
Link to electrical circuit diagram:
www.nff-janssen.de/Info/circuit_diagram

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1) Janssen cookie formers are
extremely functional in design and
are based on principles that have
remained virtually unchanged for
more than 60 years, have enjoyed
great success and have proven
themselves in practice. The combina-
tion of well thought-out design and
intelligent function is one of three
basic principles for our durable,
robust and extremely efficient cookie
moulding machines.
3 Product description
2) Ergonomics is the second basic
principle of our Janssen cookie
formers. Simple and easy handling
are our central concerns. Self-expla-
natory and intuitive operation makes it
easy to get started and assists you in
your production processes, so that you
can fully concentrate on the quality of
your products.
3) Hygiene is the third basic principle
of our Janssen cookie formers. All
parts and components are extremely
accessible and therefore are very easy
to clean and maintain. This creates
the ideal conditions for you to create
flawless, high-quality products and to
enjoy your machine for a long time to
come.
3.1 Product benefits and overview
Janssen has shaped enjoyment since 1872!
Niederrheinische Formenfabrik Janssen GmbH is a family-run manufacturing business which
has been producing high-quality cookie moulding machines for shortcrust products as well as
for the efficient processing of marzipan, gingerbread and Printen doughs since 1872 in Krefeld
am Niederrhein.
The three key basic principles
of our Janssen cookie formers

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3.2 Machine overview
Janssen cookie formers are specially designed for the individual and efficient
shaping of cookies and endless bands and are available in three sizes with
different features.
The machine sizes depend on the desired output quantity and the
baking sheets used.
Baking surface*: 100-160 m2/ hour
Hopper volume: 45 kg of dough
Max. sheet width: 450 mm
*) Depends on machine equipment
Baking surface*: 60-90 m2/ hour
Hopper volume: 25 kg of dough
Max. sheet width: 250 mm
*) Depends on machine equipment
Baking surface*: 145-215 m2/ hour
Hopper volume: 60 kg of dough
Max. sheet width: 600 mm
*) Depends on machine equipment