ROUNDER DIVIDER INSTALLATION AND OPERATING INSTRUCTIONS REVISION: Divisora Boleadora (ing) 171105 MANUFACTURER’S DATA SALVA INDUSTRIAL, S.A Ctra Nacional I Km 471 20.100 Lezo (Gipuzkoa) Spain : (+34) 943 449 300 Fax: (+34) 943 449 329  E-mail: salva@salva.es URL: www.salva.es TECHNICAL CHARACTERISTICS Type Model V A Hz Pha- kW ses No of Weight per Net Weight Portions portion gr in kg DB-30 1018/95 230/400 2.4/4.2 50 3PE 0.75 30 20 - 100 250 DB-36 1018/95 230/400 2.4/4.2 50 3PE 0.75 36 18 - 75 250 DB-22 1018/95 230/400 2.4/4.2 50 3PE 0.75 22 20 - 135 250 DB-15 1018/95 230/400 2.4/4.2 50 3PE 0.75 15 60 - 200 250 DB-30S 1018/95 230/400 2.4/4.2 50 3PE 0.75 30 40 - 135 250 DB-36S 1018/95 230/400 2.4/4.2 50 3PE 0.75 36 30 - 110 250 WARNINGS STARTING UP INSTRUCTIONS This unit must be grounded for your protection in order to avoid the risk of electrical discharges It should be connected directly to the ground terminal of the control cabinet The ground cable must not be cut or disconnected from the oven NOISE LEVEL The acoustic power emitted by the oven is lower than 70 dB Keep this instruction manual in a safe and accessible place SALVA INDUSTRIAL, S.A 0-1 Divisora Boleadora (ing) 171105.doc PREASSEMBLY INSTRUCTIONS 1.1 STORAGE AND TRANSPORT The oven is sent packed on a wooden platform and covered with a plastic film, that protects the machine against humidity and rain The oven should be transported in a completely closed vehicle and it should never be left outdoor 1.2 CONDITIONS OF USE - The machine has been manufactured to be installed indoors It has not been designed to work outdoors Any possible contact with water has to be avoided - The machine should not be installed in places with excessive heat, steam and/or humidity production - The machine is prepared to work under the following external conditions : -10 + 50 ºC, and + 90 % of humidity - The floor on which the oven is to be positioned should be PERFECTLY FLAT AND LEVELLED The machine area should be a minimum of 590 mm in width and 610 mm in depth - Enough clearance should be allowed on the machine’s left hand side to be able to lift the cutting head - For installing the machine on the floor the side covers are to be removed The machine can be fixed to the floor by means of "BRIC type" fastening bolts Some clearance must be left between the machine and the walls in order to carry out maintenance 1.3 ACCESS TO THE PREMISES The semiautomatic Divider Rounder DB is delivered fully assembled, its final dimensions are : MACHINE DB SALVA INDUSTRIAL, S.A Width Depth Height Height Weight mm mm mm mm (with lever) Kg 590 610 1.430 2.010 250 1-1 Divisora Boleadora (ing) 171105.doc INSTALLATION INSTRUCTIONS 2.1 ELECTRICAL CONNECTION This should be carried out by authorized professionals according to the regulations in the country in question The oven is delivered completely assembled and prepared to be connected to the electrical connection (400V, phases) Find in the attached board a sample of normal electric power and wire sections, following the standard EN 60204-1 for using phases wires plus ground wire MACHINE POWER CONNECTION 230 V CONNECTION 400 V DB 0,75 kW Phases + earth Phases + earth 1.5 mm2 1.5 mm2 2.1.1 Change of voltage If the current on the premises is 230 V then prior to connection it will be necessary to alter the following components accordingly: Voltage change in the terminal plates of the motor and of the heating elements It will be necessary to disassemble the bridges connected for 400 V and reassemble then with the 230 V connection, as shown in the figure IMPORTANT: Before using the machine, please ensure that the sense of rotation of the rounding plate is correct., as indicated by an arrow on the machine covers If the sense of rotation is not right two phases in the current supply would have to be swooped SALVA INDUSTRIAL, S.A 2-1 Divisora Boleadora (ing) 171105.doc 2.2 OTHER OPERATIONS Fit the wheels to the machine (if the machine was delivered with them) by pressing them into the shafts Put the safety pins in place, tighten the nuts; the wheels should rotate freely Please assemble the pressure lever into place on top of the machine and tighten the nuts Grease has been applied to protect the dividing head, it must be remove before you start to work on the dough In order to remove the grease release the bolt, lift the dividing head and clean the lower end of the dividing head SALVA INDUSTRIAL, S.A 2-2 Divisora Boleadora (ing) 171105.doc GENERAL DRAWING Pressure lever Dividing lever Rounding lever Bolt for lifting the head Main Switch Rounding volume adjustment Pressure plate SALVA INDUSTRIAL, S.A 3-1 Divisora Boleadora (ing) 171105.doc WORKING WITH THE MACHINE 4.1 WORK CYCLE DESCRIPTION Extend a piece of dough on the rounding dish and place it under the rounding table Press the dough and proceed to divide it into smaller pieces The blades are released and the cut-out portions are rounded After rounding the rounded portions are removed from the machine 4.2 ADJUSTING THE MACHINE First of all, the weight controlbar (6) should be set to the right position The position of the bar determines to what height the dividing head will withdraw for the rounding to take place This determines the volume of the rounding chambers and is therefore related to the weight of the dough piece that has to be divided The following table gives an indication of the correct setting of the weight control bar NUMBER TOTAL DOUGH WEIGHT (g.) 500 1.000 1.500 2.000 2.500 3.000 (*) NOTE (*): The minimum dough weight the semi automatic divider moulder type S can work with a minimum of 800 gr and a maximum of 4.000 gr Turn on the machine by switching on the main switch Place the piece of dough right in the middle of the moulding plate If the dough is sticky, dust the dough piece with a little flour Insert the moulding plate, ensuring it lies flat on the moulding table and that it is correctly positioned at the back under the guide and falling over the locking pin at the front Lower the pressure bar (7) down and press it down Then not let the bar loose and keep it in this position Release the dividing blades by pushing the dividing handle (2) to the right To begin the rounding, lightly push the rounding handle (3) down The rounding movement will last for as long as the rounding handle is press down The correct rounding time is a matter of experience and depends on the composition and king of dough SALVA INDUSTRIAL, S.A 4-1 Divisora Boleadora (ing) 171105.doc After releasing the pressure bar (1) the machine will return to its neutral position and the moulding plate with the buns on top of it can be removed from the machine 4.3 ADJUSTING THE MACHINE The following information will help you in obtaining the desired result When operating the machine always adjust the following factors: volume, pressing time and rounding time A) The buns not have the same weight Ensure the dough piece is put exactly in the middle of the plate and flatten it a little by hand Make sure that the dough piece not cross the concentric circles The dough pieces outside the ring will not be divided and rounded Check the pre-proofing time of the piece of dough (this will depend on dough type, however it will usually be around 15 minutes) Increase the pressing time so that a more even thickness is achieved B) Buns are not round Adjust the weight control bar (6) to a lower setting Increase the rounding time the moulding lever (3) is being pressed A combination of both C) Buns have a dot on top Adjust the weight control bar (6) to a higher setting Check whether the weight of the dough piece to be divided is in accordance with the capacity of the machine D) Buns show an opened skin The buns have been moulded intensively, too Mould the buns for a shorter time (3) E) Machine presses dough through the gap between the ring and the moulding plate The piece has been pressed for too long Decrease the pressing time and pressure NOTE: General Assembly Drawing can be found in section SALVA INDUSTRIAL, S.A 4-2 Divisora Boleadora (ing) 171105.doc MAINTENANCE INSTRUCTIONS IMPORTANT Maintenance and repair work should be carried out by the Official After-Sales-Service IMPORTANT Ensure that the main switch is turned off (0 setting) before any maintenance work is carried out on the machine Daily maintenance The rounding plate should be cleaned daily Any dough remains should be removed from the machine Hang the rounding plates on the hook provides on the right side of the machine Weekly maintenance Clean the blades, cutting head and area under the rounding table on a weekly basis For the cleaning of the cutting head proceed as follows: Remove the pressure ring (7) by turning it ¼ of a turn clockwise Turn the rounding lever adjustment (6) to its highest setting Move the pressure lever downwards and push the dividing lever to the right (in doing this the cutting head will go up and the blades will come down) After removing the bolt (4), free the pressure and lift the cutting head After lifting bring the blades out by using the pressure lever (1) Use a plastic spatula for cleaning; once cleaning is finished oil the head and the blades with an edible oil slightly; not forget to clean the pressure ring Remove the rounding table by pulling it vertically upwards with a firm pull Remove any flower or dough remain from under the rounding table Place the rounding table back into its position, ensure that the cavity under the table fits on the bearing Press the table firmly down until it settles in Return the cutting head to its original position and secure it with the bolt provided The machine is back to its neutral position Reassemble the pressure ring turning it anticlockwise The machine can now be operated in a normal manner Monthly maintenance All the moving parts of the cutting mechanism should be greased Grease all the moving parts specially the nylon surface where the rounding head slides and the eccentric movement bearing (37) Check the belt tension and tighten if necessary SALVA INDUSTRIAL, S.A 5-1 Divisora Boleadora (ing) 171105.doc month period maintenance (should be carried out by the After-Sales-Service) The electrical parts and surrounding areas of the machine should be cleaned NOTE: Lack of cleaning may cause the motor to break down prematurely NOTE: Dust and flour could provoke malfunctions in the electrical components of the control box SALVA INDUSTRIAL, S.A 5-2 Divisora Boleadora (ing) 171105.doc GUARANTEE Our products are guaranteed against every failure or manufacturing defect, within a correct use of them The guarantee does NOT apply to the substitutions and mending appearing from: - An abnormal use of the machine - The damage or accidents originated by negligence - Lack of maintenance - Defective installation or use of the devices The guarantee is limited to the replacement and repairing of parts that prove defective, being at your expense both manpower and travelling The normal guarantee period of the materials is six months In no case, not even in specials or foreseen cases, the guarantee period will be longer than one year Guarantee conditions The materials must be installed, used and kept in the conditions shown in this guide The problems which require the help of an engineer, will to be solved by the After-Sales Service Department of SALVA INDUSTRIAL S.A or by one of our distributors If these guarantee terms are not respected, the guarantee period may come to an end SALVA, in its constant search for improvement of its products, reserves the right to carry out modifications without any previous notice SALVA INDUSTRIAL, S.A 6-1 Divisora Boleadora (ing) 171105.doc ELECTRICAL SCHEME SALVA INDUSTRIAL, S.A 7-1 Divisora Boleadora (ing) 171105.doc LIST OF SPARES No in Code Description Drawing No in Code Description Drawing 1A 00001 GUIDE KEY -N- 37A 00449 CROSS BEARING -N- 1B 01363 GUIDE KEY -S- 37B 01361 CROSS BEARING -S- 60003 BEARING 3203 38 61292 DRAWING SPRING 60004 BEARING 6209 41 60552 V-BELT SPZ 825 8A 00004 TOP FRAME CASTING -N- 42A 60020 PULLEY MOTOR 50 HZ 8B 01340 TOP FRAME CASTING -S- 42B 01583 PULLEY MOTOR 60 HZ 10 60005 BEARING 6208 43 00015 SHAFT MOTORPLATE 12 60007 CIRCLIP A35 44 00016 MOTORPLATE 13 60008 BALL KNOB 46 00017 STRAINER 17 00005 MOULDING HANDLE 50 61232 MOTOR 0,55 KW 920 R.P.M PH 21 60042 NYLON BEARING 51 00018 STUD MOULDING TABLE 22 00006 PRESSURE LINK 53 60023 KEY CROSS-BEARING 24 00007 BASE FRAME 54 00019 BEARING HOUSING 00008 REAR COVER PLATE 56 01580 SHAFT CROSS-BEARING 33A 26 02407-3/15 MOULDING PLATE 15 PORTIONS IN PLASTIC -N- 63 00023 VOLUME CONTROL BAR 33B 02407-3/22 MOULDING PLATE 22 PORTIONS IN PLASTIC -N- 64 00025 PRESS HANDLE 33C 02407-3/30 MOULDING PLATE 30 PORTIONS IN PLASTIC -N- 65A 00082 COUNTERWEIGHT -N- 33D 02407-3/36 MOULDING PLATE 36 PORTIONS IN PLASTIC -N- 65B 01358 COUNTERWEIGHT -S- 33E 02452-3/22 MOULDING PLATE 22 PORTIONS IN ALUMINIUM -N- 66 60026 WING SCREW 33F 02452-3/30 MOULDING PLATE 30 PORTIONS IN ALUMINIUM -N- 68A 00925 CROSS 15 DIVISIONS -N- 33G 02452-3/36 MOULDING PLATE 36 PORTIONS IN ALUMINIUM -N- 68B 00030 CROSS 22 DIVISIONS -N- 33H 02407-4/30 MOULDING PLATE 30 PORTIONS IN PLASTIC -S- 68C 00029 CROSS 30/36 DIVISIONS -N- 33I 02407-4/36 MOULDING PLATE 36 PORTIONS IN PLASTIC -S- 68D 01352 CROSS 30/36/50 DIVISIONS -S- 33K 02452-4/30 MOULDING PLATE 30 PORTIONS IN ALUMINIUM -S- 73A 00871 GEAR RACK 15/22 DIVISIONS -N- 33L 02452-4/36 MOULDING PLATE 36 PORTIONS IN ALUMINIUM -S- 73B 00870 GEAR RACK 30/36 DIVISIONS -N- 34A 02465 MOULDINGTABLE -N- 73C 01354 GEAR RACK 30/36/50 DIVISIONS -S- 34B 02396 MOULDINGTABLE -S- 74 61291 DRAWING SPRING TOP 35A 00013 SLIDE RING -N- 75 00035 SHAFT LEVER 35B 01359 SLIDE RING -S- 81 00039 BOW SPRING TOP 36 60016 BEARING 6303 82 00040 KNIFE HOLDER 83 60031 BUFFER 89A 60036 SPRING LEVER 15/22 DIVISIONS SALVA INDUSTRIAL, S.A 8-1 Divisora Boleadora (ing) 171105.doc No in Code Description Drawing No in Code Description Drawing 89B 60614 SPRING LEVER 30/36/50 DIVISIONS 181B 60493 FOR -S- BEARING 90 60610 BALL KNOB 182A 01590 LEVER -N- CASTING 182B 01357 LEVER -S- CASTING 183 00396 SLIDING PIECE 92A 00875 LEVER 15/22 DIVISIONS 92B 00873 LEVER 30/36/50 DIVISIONS 93A 00923 DIVIDING HEAD 15 DIVISIONS -N- 184A 00395 RING HOLDER -N- 93B 00298 DIVIDING HEAD 22 DIVISIONS -N- 184B 01351 RING HOLDER -S- 93C 00299 DIVIDING HEAD 30 DIVISIONS -N- 185 60509 BALL SCREW RING HOLDER 93D 00300 DIVIDING HEAD 36 DIVISIONS -N- 186A 00450 PILOT HOLDER 15/22 DIVISIONS 93E 01344 DIVIDING HEAD 30 DIVISIONS -S- 186B 00394 PILOT HOLDER 30/36 DIVISIONS -N- 93F 01347 DIVIDING HEAD 36 DIVISIONS -S- 186C 01355 PILOT HOLDER 30/36/50 DIVISIONS -S- 93G 00000 DIVIDING HEAD 50 DIVISIONS -S- 187 60503/4/5 96A 00922 KNIFE CROWN 15 DIVISIONS -N- 189A 00400 COVER MOUNTING HOOK RIGHT CLIPS FOR MOUNTING COVER 96B 00046 KNIFE CROWN 22 DIVISIONS -N- 189B 01591 COVER MOUNTING HOOK LEFT 96C 00047 KNIFE CROWN 30 DIVISIONS -N- 193 60956 NYLON WHEEL 96D 00048 KNIFE CROWN 36 DIVISIONS -N- 194 00406 SHAFT FOR WHEELS 96E 01345 KNIFE CROWN 30 DIVISIONS -S- 199A 00398 STOP LEVER -N- 96F 01348 KNIFE CROWN 36 DIVISIONS -S- 199B 01360 STOP LEVER -S- 96G 00000 KNIFE CROWN 50 DIVISIONS -S- 200A 00051 COVER SEMI-AUTOMATIC FRONT -N- 103 00052 SHAFT SPRING TOP 200B 01388 COVER SEMI-AUTOMATIC FRONT -S- 104A 00053 BOW SEMI-AUTOMATIC -N- CASTING 201 00056 COVER SEMI-AUTOMATIC REAR 104B 01342 BOW SEMI-AUTOMATIC -S- CASTING 205 60942 LOCKING RING 105 00054 BOLT STOP 206 60803 SCREW MOUNTING COVER 107 00055 BUSH LEVER 207 60090 POP-NUT MOUNTING COVER 108 60039 RING LEVER 208 00446 SHAFT BOW LEFT 111A 00292 SHAFT PILOTHOLDER -N- 211 00458 RING WHEEL 111B 01356 SHAFT PILOTHOLDER -S- 212 60526 BOLT 120 00057 SHAFT BOW RIGHT 214 00447 STOP MOULDINGPLATE REAR 126 60043 SCREW 219 01036 HOOK 130 00060 SHAFT COUNTERWEIGHT 221 60276 NYLON WASHER 136 61115 KNURLED KNOB 223 60587 PIN 8*20 151A 60051 MOTOR SECURITY SWITCH 2.4 A 260A 00401 MOUNTING HOOK COVER FRONT -N- 151B 60500 MOTOR SECURITY SWITCH A 260B 00451 MOUNTING HOOK COVER FRONT -S- 151C 60793 MOTOR SECURITY SWITCH A 261 00451 MOUNTING HOOK COVER REAR 180A 00393 PRESSURE RING -N- 262 60802 BUSH BEARING COUNTERWEIGHT 180B 01350 PRESSURE RING -S- 263 60801 MOUNTING MOTOR SECURITY SWITCH 181A 00853 FOR -N- ROLLER 264 61286 LIGHT MOUNTING HOUSE NOTE: All parts for machines fitted with the large head are marked S There are a number of pieces that are common to all models The numbers on the drawing are followed by model specific letters SALVA INDUSTRIAL, S.A 8-2 Divisora Boleadora (ing) 171105.doc SALVA INDUSTRIAL, S.A 8-3 Divisora Boleadora (ing) 171105.doc SALVA INDUSTRIAL, S.A 8-4 Divisora Boleadora (ing) 171105.doc SALVA INDUSTRIAL, S.A 8-5 Divisora Boleadora (ing) 171105.doc LIST OF SPARES FIG CODE 83 DESCRIPTION DB-15 DB-30S DB-30 DB-36S DB-36 4060000022 Damper Ref.60031 * * * * * 4060000007 Stress ring DB 02782 * * * * * 4060000025 Nylon washer Ref.60276 * * * * * 4060000013 Bobbin 24 VDC-27W DB 62215 * * * * * 4060000004 Ball button 50x16 DB 60008 * * * * * 4060000012 Operating button DB 90023 * * * * * 4060000009 Cotter DB 02925 * * * * * 4060000002 Bearing DB 62205 * * * * * 4060000014 Switch LCF 209 DB 61765 * * * * * 4060000005 Cover axle DB 02475 * * * * * 4060000011 Main switch on M220 60049 * * * * * 4060000008 Cover fixing spring DB 02924 * * * * * 4060000020 Motor 0,55KW Ref 61232 * * * * * 4060000006 Spring DB 61921 * * * * * 89B 4060000023 Lever spring Ref 60614 * * * * * 38 4060000019 Spring Ref 61292 * * * * * 74 4060000021 Upper spring Ref 61291 * * * * * 4060000010 Tensioning spring DB 62210 * * * * * 4060000003 Locking plate DB 02926 * * * * * 4060000026 Rounding plate Ref 03017 * * * * * 4060000016 Bearing 3203 Ref 60003 * * * * * 10 4060000018 Bearing 6208 Ref 60005 * * * * * 4060000017 Bearing 6209 Ref 60004 * * * * * 193 4060000024 Nylon Wheel Ref 60956 * * * * * 4060000001 Puller DB 02472 * * * * * 221 13 50 SALVA INDUSTRIAL, S.A 9-1 Divisora Boleadora (ing) 171105.doc INDEX WARNINGS 0-1 PREASSEMBLY INSTRUCTIONS 1-1 1.1 STORAGE AND TRANSPORT 1-1 1.2 CONDITIONS OF USE 1-1 1.3 ACCESS TO THE PREMISES 1-1 INSTALLATION INSTRUCTIONS 2-1 2.1 ELECTRICAL CONNECTION 2-1 2.1.1 Change of voltage 2-1 2.2 OTHER OPERATIONS 2-2 GENERAL DRAWING 3-1 WORKING WITH THE MACHINE 4-1 4.1 WORK CYCLE DESCRIPTION 4-1 4.2 ADJUSTING THE MACHINE 4-1 4.3 ADJUSTING THE MACHINE 4-2 MAINTENANCE INSTRUCTIONS 5-1 GUARANTEE 6-1 ELECTRICAL SCHEME 7-1 LIST OF SPARES .8-1 ... letters SALVA INDUSTRIAL, S.A 8-2 Divisora Boleadora (ing) 171105.doc SALVA INDUSTRIAL, S.A 8-3 Divisora Boleadora (ing) 171105.doc SALVA INDUSTRIAL, S.A 8-4 Divisora Boleadora (ing) 171105.doc SALVA. .. INDUSTRIAL, S.A 8-5 Divisora Boleadora (ing) 171105.doc LIST OF SPARES FIG CODE 83 DESCRIPTION DB- 15 DB- 30S DB- 30 DB- 36S DB- 36 4060000022 Damper Ref.60031 * * * * * 4060000007 Stress ring DB 02782 * *... modifications without any previous notice SALVA INDUSTRIAL, S.A 6-1 Divisora Boleadora (ing) 171105.doc ELECTRICAL SCHEME SALVA INDUSTRIAL, S.A 7-1 Divisora Boleadora (ing) 171105.doc LIST OF SPARES