ABI LTD

Manufacturer of Quality Machinery for the Baking Industry

OPERATING MANUAL for the

ABI-DF-3000 BAGEL DIVIDER FORMER

WITHOUT GUARDSTHIS MACHINEDO NOT OPERATE

DANGERDANGEROF MOVINGKEEP CLEAR

PARTS

ACHINES4 5 7 7 - B L a s P o s i t a s R o a d * L i v e r m o r e , C a l i f o r n i a * ( 5 1 0 ) 4 4 9 - 3 3 6 9

Machine Type:

Model #

Serial #

Voltage:

AKING B

Amps:

M A N U F A C T U R E D B Y

M

BEFORE SERVICINGDISCONNECT POWER

DANGER

OR CLEANING

31

BManufacturer of Quality Machinery for the Baking IndustryManufacturer of Quality Machinery for the Baking IndustryManufacturer of Quality Machinery for the Baking IndustryManufacturer of Quality Machinery for the Baking Industry

Livermore, California * (510)449-3369 * FAX (510)449-2144

MAKING ACHINES

DANGEROF MOVINGKEEP CLEAR

PARTS

90

58 3/8

ABI Ltd. * 8900 Keele St. Unit 1 * Concord, ON, L4K 2N2, Canada Phone: 905-738-6070 / 800-297-8666 * Fax: 905-738-6085

TABLE OF CONTENTS 1. Introduction 3 2. Safety Warning 4 3. Inspection 5 4. Installation 5 5. Forming Belt Removal 6 6. Forming Belt Installation 6 7. Infeed Conveyor Belt 7 8. Mandrel Adjustments 7 9. Pressure Plate 7 10. Operation (Start and Stop) 8 11. Setting The Weight 8 12. Dough Loading Procedure 9 13. Lubrication 9 14. Sanitation 10 15. Spare Parts Recommended 11

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INTRODUCTION Thank you for your decision in purchasing the ABI LTD Bagel Divider Former. All of us at ABI LTD are proud to provide you the highest level of craftsmanship in our machines that will give you many years of good reliable service. Please take the next few moments to read this operating manual in order to help familiarize yourself with your new machine. For reference, please write in the model and serial numbers along with the voltage in the space below. Please refer to the serial number whenever you call our service department and request information or need parts for your machine.

Machine Type:____________________

Model Number: ___________________

Serial Number: ___________________

Voltage: ________________________

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SAFETY WARNING

DO - Read operating manual thoroughly before operating Bagel Divider Former. DO NOT -- Operate Bagel Divider Former in a careless manner or use for anything, other than its intended purpose. DO NOT - Wear loose clothing or have long hair worn down. Loose articles can be caught in moving parts of the Bagel Divider Former. DO NOT - Operate until you have complied with all local safety regulations. DO NOT - Try to operate Bagel Divider Former without safety guards. DO NOT - Operate while standing in water. DO NOT - Place hands inside guards while Bagel Divider Former has power to it.

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INSPECTION Check shipping crate for any damage prior to opening crate and signing shipping lading. After opening crate, take note of any damage to Bagel Divider Former. Report any damage to the FREIGHT CARRIER on the shipping lading and notify ABI LTD. NOTE - All knobs and fittings are tightened prior to leaving the factory. A pair of channel locks and cloth is all that is needed to loosen them. INSTALLATION Upon arrival of your ABI-DF-3000 Bagel Divider Former, it is very important that you handle it with care. Dropping or mishandling the divider former can cause the following problems: A. Bearings to move out of alignment. B. Drive and idler shafts to move out of alignment. C. Base to shift. IMPORTANT: All of the following can affect the performance of your divider former. Make sure that the rear guard is closed or the divider former will not start. NOTE: If your machine is equipped with 3 phase power, please follow the next steps. 1. It is VERY important that motor rotation is checked prior to start up, or damage may occur to drive chain tensioner. A Loosen belt tension. B. Jog start button. C. If the drive rollers travel in reverse, STOP INSTANTLY and reverse phases to change motor rotation. FORMING BELT REMOVAL: STEP 1: Remove the pressure plate by removing the four (4) knobs at the corners of the pressure plate, lift plate off and place in a safe place. STEP 2: Slacken idler pulley to the end of slots in former body by loosening the two (2) front handles. STEP 3: Open forming sleeve by removing the three (3) knobs. STEP 4: Slide belt off drive pulley and then idler pulley. Roll belt and store in a safe, clean place.

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FORMING BELT INSTALLATION: STEP 1: Make sure that the rollers are clean and that there is no build up of dough. Place new belt around idler pulley first, making sure that it is fully at the extended position in the slots on the former body, then around drive pulley with the top of the belt into the bottom half of the forming sleeve. NOTE: Bagel belts can only run in one direction. It is very important that arrows on under side of belt are pointing in the direction of travel. Always place a new arrow on belts that have been run for a period of time prior to removal. STEP 2: Roll belt up into the bottom half of the forming sleeve a little at a time until the belt is at the top of the forming sleeve. Then close the top half of the forming sleeve and install the rear knob first. As you tighten the knob halfway make sure that the belt will not be pinched, then install the middle and front knob, tightening all three with even tension. NOTE: When new belts are installed for the first time they will be very stiff and hard to place into the forming sleeve. Once they have run for a while this process will be much easier. STEP 3: Replace the pressure plate and fasten down with the four (4) knobs. STEP 4: Tighten idler pulley by tightening the two (2) front handles. STEP 5: Start former and continue to tension belt until no slippage occurs. It will also be necessary to track the belt by tightening the left or right handle. To move the belt to the right, tighten the left handle. To move the belt to the left tighten the right handle. IMPORTANT: Do not overtighten forming belt or damage may occur. Only tighten enough to keep the belt from slipping. INFEED CONVEYOR BELT: The infeed conveyor belt is the single 3” wide belt located at the top of the machine. It can be aligned by tightening the tensioner bolts at the rear of the conveyor bed. The belt should not rub against the plastic sides of the conveyor bed. MANDREL ADJUSTMENTS The mandrel has four (4) adjustment knobs that are located on top of the forming sleeve Loosen the knobs to adjust up and down and side to side. STEP 1: It is important that the mandrel is parallel to the forming sleeve. When making adjustments make sure this is accomplished. STEP 2: The mandrel may operate best on some products when it is slightly off center toward the bottom side of the forming sleeve. Insure that all knobs are tight when adjustments are complete.

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PRESSURE PLATE The pressure plate creates the molding action and the arch in the dough piece before it enters the forming sleeve. There are three (3) adjustments that set the top pressure plate. The front adjustment provides the amount of molded arch in the dough piece while the two (2) back sets control the molding action and length in order to distribute even pressure on the dough piece. STEP 1: As the dough piece is transferred from the divider, the pressure plate entrance should be set to where it just starts to grab the dough and starts a rolling action. This can be accomplished be loosening the top two (2) rear knobs then tightening the rear lower two (2) knobs. NOTE: If the dough piece slides under the entrance of the pressure plate it should be lowered, or the possibility of doubles may occur, along with bagels that are not molded properly. NOTE: If the dough is pinching when it reaches the forming sleeve the pressure plate needs to be raised until the pinching stops. This usually can be accomplished by adjusting the front portion of the pressure plate. STEP 2: The front knob should be set so that the dough length is just to the point of where it just starts to come together when it enters into the forming sleeve. The up and down movement can be accomplished be loosening the top knob at the front of the pressure plate and then moving the lower front knob up or down. After this is complete, tighten the top knob. NOTE: The pressure plate also can be moved side to side. The proper setting should be in the middle of the belt. OPERATION- START AND STOP 1. Plug Divider Former into a wall outlet capable of supplying 120 volts, 1 phase, 15 amps. 2. Check to insure that rear door is closed. 3. Check to insure infeed safety and dough sensor roller is free. 4. Check to insure no tools or miscellaneous items are left on Divider Former. 5. To start Divider Former, pull the red button on the Divider Control Panel. This is a two

position start and stop button. The first click will provide power and the second click will start the former.

6. Once the former has started, there will be a four second delay before the divider will be able

to start. (This insures all dough is clear in the former.) The next step is to start the divider. This can be accomplished by looking at the keypad on the control panel. When the status light turns red, the four second delay has passed.

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7. Push the forward key on the pad, this will start the divider. To stop the divider push the stop key.

NOTE: If a complete stop or an emergency stop is needed, the red button used in step five can be pushed in. This will stop the machine instantly.

NOTE: If the machine is stopped completely for more than two minutes, with

dough still in the bagel former, the dough should be removed prior to restarting, or it will begin to stick to the belts.

8. To restart, repeat steps 2 through 7. SETTING THE WEIGHT: 1. The machine must be in full running operation before the weight can be adjusted. Using the

scroll pushbuttons on the weight display, adjust the up and down arrows to the desired weight. The number in the LED display window will increase or decrease. This number is not the actual weight. It is to be used as a reference indicator until the desired weight of the bagel is achieved.

2. After the number in the display has been chosen, wait 3 to 4 seconds and check the bagel on

the scale for actual weight. Continue to increase or decrease the number in the display window until actual weight is achieved, waiting 3 to four seconds between each check. Press the enter key when final weight is achieved. This will store the weight reference number into memory. If the machine is later turned off or unplugged the number will default back when the machine is restarted.

NOTE: If the enter key is not pressed after the desired setting has been selected, the

setting will not be in memory. So if the machine is turned off and then restarted, the last setting that was in memory will return. The remaining function keys,(program, function, reverse, and jog), are only for authorized service and program use. These function keys will not operate for the operator.

DOUGH LOADING PROCEDURE It is imperative to the operation of the divider former to load the dough consistently. Dough pieces should be cut to the width of the infeed belt and approximately 1/2” below the height of the side rails. When loading consecutive pieces of dough, lift the tail end of the previous piece and place the leading end of the following piece underneath, giving an overlap of two to three inches. Hand crimp the two pieces together to insure smooth dough flow. Insure there are no side gaps in the dough. This will cause uneven weights.

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LUBRICATION The bagel divider former has been lubricated prior to leaving the factory, and is ready to run. Maintaining a proper lubrication schedule is essential to the performance and life of the divider former. We recommend that after every 300 hours the divider former should be lubricated. FORMER BEARINGS The front take up roller is equipped with sealed bearings and does not require grease. The rear drive roller bearings should be lubricated with a multi-purpose or FDA food grade grease. DIVIDER BEARINGS The cutter shaft bearing is located on the left side of the divider. There is one bearing that will require grease. The remaining parts of the divider do not require any grease. NOTE: Bearings should not be over greased as to protect bearing seals. If this should occur, simply remove zert fittings from the bearing and run former briefly to remove excess grease. IT IS VERY IMPORTANT THAT THE ZERT FITTINGS ARE RETURNED TO THE BEARINGS. CHAIN The chains on the divider consist of the cutter shaft, sheeting rollers, and clutch. They all should be kept free of dirt and flour to insure life of chain and gears. Any spray-on graphite lubricant will be sufficient for lubricating the chain. MOTOR and GEARBOX The motors should be greased every 300 hundred hours along with the bearings. The gear boxes should be drained every 12 months and filled with SAE 90W gear oil.

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SANITATION Disconnect power to the DF-3000 before beginning any cleaning on the divider former. Former The bagel divider former should be cleaned after every eight (8) hours of continuous operation. The former belts should be removed from the drive roller ( follow instructions under belt removal). Clean the drive roller with a soft plastic scraper to loosen any large pieces of dough that may be present, then use a rag with warm water to soften any hard dough and wipe clean. Clean the idler roller with a plastic scraper and remove all dough residue. Open the forming sleeve and clean any dough build up. Scraper Assembly Begin by removing the top pressure plate. With a 1/2 wrench remove the two bolts that secure the scraper assembly to the shaft. Remove the scraper assembly from the divider and brush off all loose particles of dough. Wash the scraper assembly with warm water and a sanitizing solution. Reinsert the scraper assembly into the divider and fasten the two bolts securely to the shaft. Cutter Blade Using the on/off switch rotate the cutter blade until the two bolts face the rear of the divider. Disconnect power to the DF-3000 and open the rear cover. Remove the two bolts that secure the cutter blade to the shaft and remove the blade and the backplate. Wash the plastic blade and backing plate with warm water and a sanitizing solution. Using a rag with warm water wipe the shaft clean. Reinsert the cutter blade making sure the blade is pointing upward. Insert the two bolts and tighten securely. Divider Head Remove the top pressure plate and the scraper assembly. Using a plastic scraper remove all dough build up from the rollers and shafts. Using a rag with warm water and a sanitizing solution clean all exposed surfaces. Close the cover and jog the divider until the non exposed sides of the rollers are exposed. Open the cover again and clean all exposed surfaces. Repeat this process until all rollers are clean. Using the provided cleaning tool, clean thoroughly between the main drum and the side plates. Remove any dough build up or particles that may have fallen between the side plates. NOTE: 1) DO NOT use a metal scraper to remove dough from the drive roller, or any other parts on the divider former. 2) DO NOT attempt to clean when the machine is in operation or severe damage or injury may occur. 3) DO NOT attempt to disconnect or by-pass the safety switches. 4) DO NOT use water to clean the forming belts, use a soft brush or plastic scraper.

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ABI LTD DIVIDER FORMER ABI-DF-3000

Recommended Spare Parts List

Recommended Part Number Description Quantity Vendor DF122BZ Cutter Blade 1 ABI LTD DF114BZ Cutter Blade Back Plate 1 ABI LTD SBR103 Limit Switch 1 ABI LTD ABC-20 20 amp fuse 5 ABI LTD AGC-5 5 amp fuse 5 ABI LTD B-2 52 X .25 Endless O Ring Belt 1 ABI LTD 2-5001 1.75 X .25 O Ring 1 ABI LTD *BTA__________ Forming Belt 1 ABI LTD *Belt size dependent on quick change size. Note: Forming belt of choice should also be included - call for size choices Note: For a listing of our current prices, please call our parts department at 905-856-87-88 / 800-297-8666.