Janssen SELECTRONIC A User manual

FM128 K250…K600
Niederrheinische Formenfabrik
Gerh. Janssen & Sohn GmbH & Co. KG
Moerser Straße 33 • D 47798 Krefeld
Tel. [phone] • Fax [phone]
www.nff-janssen.de • [email protected]
Operating instruction SELECTRONIC-A
(Translation of Original Operating Instruction)
Cookie former
Version:
04_2013_en
jan_anl_K250_600_04_2013_en.indd

»Congratulations to your new cookie machine.«

3
Niederrheinische Formenfabrik
Gerh. Janssen & Sohn GmbH & Co. KG
Contents
Operating instruction
page contents
4 Safety regulations and security precaution
5 Proper use
5Food hygiene
6 Operating instruction
11 SELECTRONIC-A control
15 Drive schematic FM 128 K
15 Defects and their repairs
16 Connection and assignment
17 Technical Data
18 EC Declaration of Conformity
Attachment
A1 Annex: General for dough
Recipes
Operation with baking paper
Treatment recommendation for shiny blue sheets
A2 Annex: Spare parts list K250…600 Selectronic-A
AAnnex: Maintenance instructions for replacing belts
AAnnex: Operating instruction for knife installation
AAnnex: Operating instruction for knife guard installation
AAnnex: Operating instruction for sliding ring and sliding pin

4
Safety regulaions and security precautions
Machine is ready to use, as it is supplied.
Disconnect plug when attendance or repair machine.
Before you begin, read operating instructions!
The machines of type FM 128 K 250, 300, 400, 450, 580 and 600, are tted with the
following safety equipment:
Security precaution of rollers
In front of the roller is mounted a Plexiglas cover in front of the funnel with a hinge.
The Plexiglas cover is held laterally by guide rails.
Security precaution of knife
The machine has a knife guard, which automatically lays down on the knife when you
open the dough hopper and thus excludes an injury.
Security precaution of hopper
The hopper is equipped with a safety switch that shuts off all the movements while
lifting. It is impossible to manipulate the safety switch.
Scurity precaution of lift grid
The machine stops immediately when you open the grid above the hopper.
Security precaution of transport belt guard
The transport belt for the back plate is provided with an inlet protection.
All protective covers and panels are bolted and can only be
opened with tool!

5
Proper use
As the name molding machine already says, the machine is suitable for forming short-
bread like biscuits, spekulatius, milanese and cakebases (for cream cakes and other
cakes, lattice of dough (for tarts), tartelettes, brezel, linzer, kipferl, etc.
White cakes, brown cakes, gingerbread, and marzipan can be formed by special
rollers.
Food hygiene
The machine should be stored in a dry place. As a cover, we recommend a linen tape.
Please do not use a plastic cover, because it may arise a humid climate under the
cover, which can lead to mold and vermin infestation.
The linen tape should be cleaned or exchanged as required (dry cleaning).
After use, it is important to clean the machine.
Clean all interior and exterior surfaces, corners and edges which are accessible with a
lint-free cloth.
Intermediate the lint-free cloth in warm soap water, before further wipe.
Do not steam clean or use a jet of water.
The machine has to be isolated from mains supply before carrying out
any cleaning!

6
Operating instruction
Congratulations to your new cookie machine.
1. Unpacking the machine
If you nd a damage on the unpacked machine, call your agent and let him see the
damage, so that the damaged machine can be replaced.
2. Connect the machine
Before plugging the machine, get sure, that electricity network has a voltage
of 3 x 400V + MP + protective conductor. the machine is set by this specifcation.
With 3 x 230 + MP + protection manager, the engine of the machine is reversed ac-
cordingly. If you have the correct voltage with the appropriate socket, you can let the
machine run on trial basis. If the machine is running backward, stop the engine imme-
diately and disconnect the power plug from the can.The machine is wired clockwise. It
is banned to manipulate the clockwise rotation of connection.
Let, if necessary, your socked change by a licensed electrician!
If the machine is permanently connected without a rm plug, the machine needs an
additional main switch.
3.1. Beltregulation / upper transport belt
The upper transportbelt, wich takes the gures from the knife, can be adjusted by hex
nut M18 on spindle thread on both sides. Please regulate only few and do not tighten
the belt too fast, because the belt takes some minutes to regulate.
If possible take always just one side to regulate, because otherwise the tension of the
belt greatly increases unnecessarily. The belt gets narrow and snatches in extreme
rase.
3.2. Beltregulation / lower tranport belt
The lower transport belt must not be adjusted.
They are connected by connectors and can be exchanged easily.
4.1. Speed regulation of transport belt
The speed of the lower transport belt can be in connection with the speed of the ma-
chine, regulated by Selectroniccontrol.

7
5. Changing of pattern roller
Flip the hopper gently to the front. After removal of the pattern roller plug or lock pin
out of ange axis draw the left ange from the pattern roller, and pull the roller now out
of the right ange.
Now you can take off the roller from the uppon. The installation is done in reverse
order.
6. Removing and cleaning of the roller
By developed rollers, access - standing behind the machine - with the right hand into
the left Griffuge the kneading rollers.
Drag with the left hand, the retention pin from the ange axis and pull the ange, as far
as possible, outwardly.
Now access to the kneading rollers, that is, the left hand into the left Griffuge and the
right hand into the right handle groove. While the kneading rollers lay in the sheet me-
tal engine cover, you can slowly lift the rollers out of the machine. For cleaning put the
roller on the side of the drive holes (red mark) and pull the dough from the roller with a
scraper. Subsequently, the roller in the dishwasher (not more than 60°C), cleaned with
high pressure cleaner or with the scrubbing brush with warm water by hand.
7. Knife position
The knife is driven by an eccentric and moves very fast on the strip of dough along the
kneading roller. The position of the knife to the dough sheet, remove closer (thicker) or
further (thinner), can be adjusted with the lever on the front of the machine. The best
position is directly above the strip of dough, but very deeply engraved gures can be
cutted quite a bit thinner (see also 8, the Cut-off).
The basic setting is: 3. line from above.

8
8. The cut-off knife
The knife of the cookie machine is special coated to prevent sticking of the gures,
especially when the dough is sticky. Please avoid using sharp or hard objects to
clean the knife. A woolen cloth, soaked in comestible oil should be taken for that.
The position of the knife should be in the middle position at the start.
Thicker: The cookies will be thicker, when the distance between the knife
and the belt of dough on the kneading roller is lower.
Thinner: The cookies will be thinner, when the distance between the knife
and the belt of dough on the kneading roller is larger.
The basic setting is: 3. line from above.
The knife can be terminated with levers placed on the left side of the Plexiglas plate
- Thick - Thin - on the optimal character strength.
The knife is very thin and very narrow, in order to provide optimal results.
Therefore the thickness adjustment must be undertaken with caution to not jeopardi-
ze the knife. The standard setting is about the 6th Line from below.
When dough with swelling factor, like already risen dough with a leavening agent, it
may be that the optimal setting of the knife position is below.
The optimum thickness of gures is chosen when the gures are formed without any
irregulatities at the edges.
Is the lever switched upwards, (thick) thus forming one additional doughlm next to
the gure, which is undesirable.
By abrasion of the cutter drive, the lever require slight adjustment after some time,
because on the eccentric the slide pin and the slide ring are going to wear out.
You can see that from the gures, wich get thinner.
By rotating the two parts, the original condition can be restored.
If you have your dough kneading roller, including a coat of dough, and passed a long
time has left, it is required to switch the knife adjustment on thin and reset very slow-
ly and carefully on the right position while the machine is running.
Never set the lever in the lowest position while the machine is lled with dough.
Don‘t use the lever in any case to peel the dough. The knife could be drawn
into the feeding roller and break!
Never set the lever with a jerk at the upper position, because it is forced, in
this case, the knife in a position that can cause a breakage of the blade, or the
knife can draw into the feeding roller.
9. Warming up the machine (pre-heating of the rollers)
If you are unsure whether you need the heater to warm up the roller, you should
always take the pattern roller and warm up a bit.
For this just turn the main switch on (ON), the mode switch on (PERMANENT) and
the heater switch on (I). In this position, let the machine run about 5 minutes, with
high-fat dough with heater switch on (II) some minutes longer.
When the roller is warm enough, you can start with the lling of the dough.
Teon rollers are usually not heated!
For Sticky dough with honey or syrup the heater may be turned off!
In honey / syrupdoughs with fat, it may be necessary to turn the hea-
ter on!

9
10. Filling of the hopper with dough
Dough can be pushed from the top of the hopper, either in slices, which t through the
bars, or it can be pushed through the bars into the hopper directly.
You can also open the bars and enter the dough into smaller pieces or slices.
First, the rear kneading rollers (checker, lling, feeding roller) must be covered with
one coat of dough. Only when the roller is completely covered with dough, the machi-
ne forms perfect gures. Now, push the lever for the knife as far as setting of, until the
gure is truncated at full strength. So the knife cuts the pieces of the dough kneading
roller and passes them onto the upper transport belt.
11. Bring the gures on tray
Now turn the switch from (PERMANENT) to (AUTO) and the machine back on (ON).
The machine is now controlled by the metal contact switch, located under the front
edge of the upper transport belt.
The baking sheets are introduced exclusively from the back of the machine.
The machine turns on by reaching the sensor at the front edge of the upper transport
belt. The gures are now automatically transferred from the upper band to the baking
sheet.
(The following applies only two mechanical switches: If you need to adjust this one,
because, for example, your baking sheets are a little narrow, be sure to hold on the
posterior part of the smooth switching lax a nger against the switch before you turn
the switching lax!)
12. One-man operation
If the tray is full, the machine is switched off with the switch contact plate. This gives
you a chance to remove the sheet and to introduce an new sheet into the machine wit-
hout needing an extra person. If you are working with several people at the machine, it
may be useful to switch the machine on (PERMANENT). Don´t forget to rell dough in
time. There should always be dough for only 2 to 3 sheets in the hopper, that means,
the space between the kneading roller and the grid should be half full.
13. Distances on the baking sheet
For very soft dough, it is possible that the gures push together on the knife. Ne-
vertheless, to achieve an optimal assignment sheet, change the speed of the lower
transport belt and proceed as described in 4.

10
15. After work
Take out both rollers and wash them completely (dishwasher, high pressure machine
or with warm water and a brush).Clean the backside of the knife carefully with oiled
cloth.
Attention: The Knife is very sharp! When you lift the blade protection,
be very carefull, to avoid cutting your ngers.
Clean only with linen cloth.
Now you take the crumb tray under the kneading roller out of the machine and clean
the area of the sheet passing through with compressed air, if available, otherwise with
a brush. The stainless steel parts of the machine (hopper-and cladding sheets), can
be cleaned with soapy water and then wiped with clear water. When the machine is
totally exempt from dough residues, the machine will be reassembled in reverse order
for the next working day.
Tip
If you have several products, go on this way. Write down the values i.e. numbers, so
you can rend the values and can reciprocate them.
roller no. V1 V2 V3 < > N Auto/Perm Haeter dough

11
ON/
OFF
Auto.
Perm.
H1
H2 Mode
V
1
V
2
V
3
<>
N
ON/
OFF
Auto.
Perm.
H1
H2 Mode
V
1
V
2
V
3
<>
N
SELECTRONIC-A
SELECTRONIC A Controller
The machines of the FM 128 K
series are equipped as standard
with a Selectronic A controller.
Keypad explanation:
1…………. On/Off button – the LED is lit when in the switched on state.
2…………. Button for Automatic or Permanent operation – pressing the button repeatedly
allows the operator to switch back and forth between Automatic (Auto.) and
Permanent (Perm.). The machine must be in the Off mode (LED for button 1 not lit).
3…………. Button for the heater – pressing the button repeatedly
allows the operator to switch the heater on or off at Level I or Level II.
- If the LED (H1) is lit, heater level I is active.
- If the LED (H2) is lit, heater level II is active.
- If neither LED or both LEDs are lit, the heater is off.
4…………. The Mode button is used to select up to 5 menu items
(see the note to the right in this regard). The selected menu items (5,6,7,8,9)
are lit respectively below.
5…………. When this LED (V1) is lit, you can read out the speed of the pattern roller on the
lower display (11) or use the arrow buttons to the left and right (10, 12) of the
display to change it.
6…………. When this LED (V2) is lit, you can read out the speed of the upper conveyor belt
on the lower display (11) or use the arrow buttons (10, 12) to the left and right
of the display to change it.
7…………. When this LED (V3) is lit, you can read out the speed of the sheet transport
on the lower display (11) or use the arrow buttons (10, 12) to the left and right
of the display to change it.
8…………. When this LED (< >) is lit, you can read out the spacing of the shapes which are
placed on the sheet on the lower display (11) or use the arrow buttons (10, 12) to
the left and right of the display to change the spacing or simply decrease it.
9…………. When this LED (N) is lit, you can read out the number of rows of shapes on
the baking sheet on the lower display (11) or use the arrow buttons (10, 12)
to the left and right of the display to change it.
10/11/12…. Values can be read out on the display (11) or they can be changed using the arrow
buttons (10, 12) to the left and right of the display.
13………… the hopper symbol with the associated LED (13) indicates, whether
the safety switches are closed correctly. When the LED is lit, then either
E1 or E2 is shown on the display:
E1 = The emergency stop button is active or is being pressed.
E2 = The hopper is not closed.
E0 = Communication error (this error message should usually disappear
again after 5-10 seconds. If it does not, please call customer
service: [phone]).
ON/
OFF
Auto.
Perm.
H 1
H 2 Mode
V1
V2
V3
< >
N
ON/
OFF
Auto.
Perm.
H 1
H 2 Mode
V1
V2
V3
< >
N
SELECTRONIC- A
13
12
1
5*
6*
7
8
9
10
11
4
2 3
*) Note:
5*:
The V1speed
change of the
pattern roller is
only available if
the machine is
equipped with a
variable motor.
6*:
The V2speed
change of the
upper conveyor
belt is only
available if the
machine is
equipped with an
upper conveyor
belt adjuster.

12
X
X
X ≈ X
You can work with the SELECTRONIC A in three
different ways:
Permanent operation
(continuous operation)
You can feed the sheets into the machine
continuously – this is also the operating mode for
pre-warming the roller.
Please optimise the sheet speed during the rst
sheet passes (see page 14 “Adjusting the sheet
speed”).
Now press button (2) for permanent operation (the lower LED on the button will
light up).
Now switch the machine on (1). The machine will run until the ON/OFF button (1) is
again pressed.
Automatic operation (sensor operation)
Automatic operation is useful when only one person is operating the machine.
The machine shuts off automatically when the sheet has been completely lled with
cookies.
There are two different modes for this (they are described in more detail below):
A) Normal automatic sheet lling (Line-line mode)
B) Automatic sheet lling with specication of the cookie rows
The dough sensor must be set to the correct height (about 2 mm above the cookie)
and at the centre of a row of cookies.
Use the sheet sensor under the leading edge of the upper conveyor belt to control the
correct positioning of the beginning of the sheet and thereby the depositing of the rst
cookie on the sheet.
Now switch the machine on (1). Insert the baking sheet into the machine from the
back. The sensor recognises the sheet and the machine will run until the sheet is
completely lled with cookie rows or until the ON/OFF button (1) is again pressed.
Note: If the next sheet is inserted immediately following the previous one, the machine
will not stop, but will begin lling the next sheet. This is why the already-lled sheet
must be removed from the machine in time so that it does not fall down from the sheet
transport unit in front. The spacing should be about 2 nger widths so that the sheet
sensor can differentiate between the sheets.
Automatic operation (A) – Normal automatic
lling of the sheet (Line-line mode):
This function should preferably be selected
when the spacing of the cookie rows on the sheet should
be about the same as the spacing of the rows
of shapes on the pattern roller.
1) To do so, press the mode button (4) until
LED (9) below lights up. Then press
the arrow button (10, 12) until two lines can be
seen on the display (11).
2) Now press button (2) for automatic operation
(the upper LED on the button will light up).
Inserting the baking sheet causes the machine to
start.

13
X
Y
X ≈ X
Y < X
Automatic operation B) –
Automatic sheet lling with specication of the
cookie rows:
This function should preferably be selected when
the spacing of the cookie rows on the sheet should
not be too large and therefore smaller than the
spacing of the rows of shapes
on the pattern roller.
This could be the case for special shapes which,
due to technical reasons, cannot be engraved on
the roller circumference optimally, e.g. a large
St. Nickolaus with a length of over 14 cm. This can
only be engraved on the roller circumference (393 mm) twice. With Permanent, there
would be a large gap between the rows of shapes on the baking sheet.
Here, the automatic function offers the option of reducing the spacing on the sheet to
achieve a better utilisation of the surface of the baking sheet (see the gure).
In automatic operation, you can now enter the desired number and spacing of the
rows of shapes on the sheet (trial and error! – it depends on sheet speed and sheet
length).
1) Set the number N of the cookie rows on the sheet:
To do so, press the mode button (4) until LED (9)
in the mode eld below lights up.
Then press the arrow button (10) until the desired
number of cookie rows (e.g. 8) on the sheet is shown on
the display.
2) Set the spacing <-> of the cookie rows relative
to each other on the sheet:
To do so, press the mode button (4) until
LED (8) below lights up.
Then press the arrow button (10, 12) until
the desired spacing of the cookie rows on the baking sheet is
shown on the display (11).
The spacing must be set using repeated trials.
3) Now press button (2) for automatic operation
(the upper LED on the button will light up).
Inserting the baking sheet causes the machine to start.
Adjusting the sheet speed V3
The sheet speed V3 can be set either faster or slower relative to the speed of the
upper conveyor belt (this can also be done during operation).
1) To do so, press the mode button (4) until LED (7) below lights up. Then press the
arrow button (10, 12) until the desired speed of the sheet transport belts is shown on
the display (11).

14
Adjusting speed V2
of the upper conveyor belt
This function is only available when a separate
upper conveyor belt is installed.
The speed V2 of the upper conveyor belt can be
set either faster or slower relative to the speed
of the pattern roller (this can also be done during
operation).
This speed setting can be necessary to slightly
stretch or compress a cookie during forming.
Classic applications are the forming of round baked pastry cases, large cookies or
continuous bands of dough.
Especially for continuous bands of dough, having the upper conveyor belt run more
slowly can prevent the band of dough from tearing.
1) To do so, press the mode button (4) until LED (6) below lights up. Then press the
arrow button (10, 12) until the desired speed of the upper conveyor belt is shown on
the display (11). The correct value can only be determined through repeated trials.
Adjusting speed V1
of the upper conveyor belt
This function is only available when a separate variable motor is installed.
The speed V1 of the entire machine can be set either faster or slower (this can also be
done during operation).
This speed adjustment could be necessary to synchronise the cookie forming with
the speed of the downstream conveyor oven. Furthermore, it can be helpful in the
case of very thick pieces of dough that are not lled in completely otherwise to run the
machine more slowly.
1) To do so, press the mode button (4) until LED (5) below lights up. Then press the
arrow button (10, 12) until the desired speed of the upper conveyor belt is shown on
the display (11). The correct value can only be determined through repeated trials.
After completing work, the machine must be switched off by means of
the main switch on the side of the machine!
Pull the plug from the mains!

15
Drive scheme FM 128 K
Selectronic without motor for
the knife
46
7
1
2
10
8
9
3
5
13
12
11
Selectronic with motor for
the knife
1… motorshaft: gear/small = 15 teeth, gear/big = 45 teeth
2… intermedicate shaft: gear/small = 15 teeth, gear/big = 45 teeth
* V-beltpulley / knife drive
3… pattern roller: gear = 50 teeth + knife drive/pinion
4… kneading roller: gear = 88 teeth
5… knife drive with bevel gear
6… upper transport belt drive: intermediate gear = 15 teeth
7… upper transport belt drive: intermediate gear = 17 teeth
8… direct current motor for tray transortation + gear 14 teeth
9… gear for drive rear transport shaft 38 teeth
10… drive belt for knife drive: 8 x 775
11… mainswitch
12... selectronic mainboard
13... transformer 18 V
14... motor for knife drive
46
7
3
14
5
13
1
2
8
9
12
11

16
Connection and assignment of a 5-pin 230/400 volts
CEE plug or outlet
Our machines of the series M250, 400, 450, 580, 600 and K250, 400, 450, 580, 600
require a 16 amp. socket.
All machines require both the 230/400 and the 230 volts function.
Our machines are connected at the factory to run right.
The drawing shows a top view at outlet in cap raised,
or a plug from the wiring side.
protective conductor color of cable: yellow/green
N Neutral color of cable: blue
L1 Phase 1 color of cable at plug: brown
L2 Phase 2 color of cable at plug: black
L3 Phase 3 color of cable at plug: black or gray
Between the phases L1 + L2, L2 + L3 and L1 + L3 must be a voltage of 380 - 440
volts present, between the phases L1 + N, L2 + N and L3 + N a voltage of 220 – 240
volts.
Let these measurements prior to connecting the machine by a professional.
The change of direction of rotation are only by changing the phases L2 + L3 against
each other.
For damage to relay, roller heating, motor and electronics by a faulty electrical outlet or
by improper changing of the phases of the machine, we accept no liability.
The machine must be connected only to a properly connected and
accepted building systems, which also has a FI (fault current protec-
tion) are secured.
Test in a six-monthly periodic the electrical equipment of the machine
to perform BGV A3.

17
Technical data
The noise of the machine is under 70 db (A).
Technical amendments reserved - Stand 2008
Designation
Table machine
K 250 K 400 K 450 K 580 K 600
Tray-/ rollerwidth
(mm)
250 400 450 580 600
Occupancy width ca. 205 ca. 370 ca. 405 ca. 560 ca. 560
Capacity in normal
operation (m2/min)
ca. 1 ca. 1,6 ca. 1,8 ca. 2,3 ca. 2,3
Power (KW) 2,3 4,5 4,5 4,5 4,5
Motor 230/400 V 0,37 0,37 0,37 0,37 0,37
Variomotor possible possible possible possible possible
Heater (W) 2 x 1000 1 x 2000 1 x 2000 2 x 2000
(An-
schluß-
2 x 2000
(An-
schluß-
Emergency stop yes yes yes yes yes
Addotional start no yes yes yes yes
Dimensions of table
machine in working
position (mm)
lenght
wide
height
1265
580
630
1450
805
670
1450
805
670
1450/2350
955
670
1450/2350
955
670
Dimensions of open
base, short and long
version (mm)
lenght
wide
height
590/930
565
635/641
900
815
645
900
815
645
900
965
645
900
965
645

18
EC declaration of conformity
(in terms of the EC directive machines 89/392/EWG, Annex II A)
We hereby declare that the construction of cookie machine
FM 128 K Nr.:
is according to the following relevant provisions:
Machinary directive 89/392 EWG with 91/368 EWG + 93/44 EWG
Low voltage directive 73/23 EWG + 89/336 EWG
applied harmonised standarts, in particular DIN EN 294, DIN EN 349,
DIN EN 60204
applied national technical specications, in particular
DIN 45635 Teil 1 + 29, DIN V 8418.
This CE Declaration goes out and lose their validity when the machine have been
used for other than the intended purposes or the manufacturer have not been agreed
modications to the machine.
Niederrheinische Formenfabrik
Gerh. Janssen & Sohn GmbH & Co. KG
................................................
Dr. Petra Gersch
(Geschäftsführerin)

19
Electronical diagram - SELECTRONIC-A