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Fusion Compact Pro Bread Plant, Rev. A21 14-04-21

1.0 INTRODUCTION

The

Mono FUSION

COMPACT

PRO

bread plant

is a fully integrated unit enabling rapid

change of product lines without moving any items of equipment.

It consists of four machines:

1. DIVIDER ……………..

Divides the dough to size required

2. ROUNDER

…………...

Rounds the dough ready for even proving

3. PROVER …………….

Allows the dough to prove

4. METRO

MOULDER

Moulds dough to shape required

DIVIDER

METRO MOULDER

PROVER

CONICAL ROUNDER

Summary of Contents for Fusion Compact PRO

Page 1: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 BREAD PLANT OPERATING AND MAINTENANCE MANUAL DIVIDER PROVER MOULDER Compact PRO fusion ROUNDER Enter Serial No s here www monoequip com FILE 133...

Page 2: ...OR YOUR SAFETY Indicates a hazardous situation which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided will result in electric shock Indicates...

Page 3: ...specification requirements of IEC 60947 Your attention is drawn to BS 7671 2018 Guidance Note 8 8 13 Other locations of increased risk It is recognised that there may be locations of increased risk o...

Page 4: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 2...

Page 5: ...ON 1 BREADPLANT ASSEMBLED INSTALLATION Prover Divider Moulder Rounder CLEANING MAIN CONTROLS BREAD PLANT OPERATION SECTION 2 DOUGH DIVIDER DETAILED MAIN INSTRUCTIONS SECTION 3 MOULDER DETAILED MAIN IN...

Page 6: ...eneral Divider Rounder and Moulder 15 6 0 ISOLATION Emergency stop buttons 20 7 0 CLEANING 21 Prover Daily cleaning 22 Weekly cleaning 23 Carrier pocket removal 23 Divider Daily cleaning 24 Weekly cle...

Page 7: ...L DIMENSIONS 41 3 0 SPECIFICATIONS 41 4 0 SAFETY 42 5 0 INSTALLATION 43 6 0 ISOLATION 45 7 0 CLEANING INSTRUCTIONS 46 Daily 46 Weekly 50 8 0 OPERATING 51 9 0 MAINTENANCE 54 10 0 TROUBLESHOOTING 56 11...

Page 8: ...4 0 SAFETY 73 5 0 INSTALLATION 74 6 0 ISOLATION 75 7 0 CLEANING 76 Daily 76 Weekly 78 8 0 OPERATING INSTRUCTIONS 79 How the Metro moulds dough pieces 79 Operating the Metro moulder 80 Starting the Met...

Page 9: ...Y 93 5 0 INSTALLATION 94 6 0 ISOLATION 95 7 0 CLEANING 96 8 0 OPERATING CONTROLS 97 9 0 TROUBLESHOOTING 98 10 0 SPARES AND SERVICE 99 FOR SERVICE AND SPARES RING 01792 564044 11 0 MOULDER ELECTRICAL I...

Page 10: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 8 BREADPLANT ASSEMBLED SECTION 1...

Page 11: ...it enabling rapid change of product lines without moving any items of equipment It consists of four machines 1 DIVIDER Divides the dough to size required 2 ROUNDER Rounds the dough ready for even prov...

Page 12: ...4 04 21 10 2 0 GENERAL DIMENSIONS PROVER METRO MOULDER DIVIDER Height 1313mm Depth 1601mm Width 739mm Height 1526mm Depth 1065mm inc conveyor 1860mm Width 670mm Height 2500mm Depth 1075mm Width 1225mm...

Page 13: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 11 CONICAL ROUNDER Height 1490mm Depth 960mm Width 960mm...

Page 14: ...1 12 2a OVERALL DIMENSIONS PLAN VIEW DIMENSIONS IN MILLIMETRES TOTAL AREA REQUIRED 1794 X 3945 HEIGHT PROVER 2500 1794 3945 POWER SUPPLY IN 3 phase neutral and earth fused at 16amp The supply to this...

Page 15: ...fused at 16amp ALL MACHINES CONNECTED TOGETHER POWER 5 kW PROVER POWER 0 37kW WEIGHT 400 kg NOISE LEVEL Less than 85dB MOULDER POWER 0 75kW WEIGHT 230 kg NOISE LEVEL Less than 85dB DIVIDER POWER 3 2k...

Page 16: ...operating instructions in this manual are required to operate this machine safely The owner and the operator are responsible for operating this machine safely DO NOT TRY TO DISABLE ANY SAFETY DEVICES...

Page 17: ...rical box 3 Insert rounder plug into the correct socket on the front of the prover electrical box 4 Insert divider plug into the correct socket on the front of the prover electrical box 5 Insert mould...

Page 18: ...e can be pushed on the castors provided beware of unlevel ground To lift with a forklift the machine must be secured to a pallet To lift with a crane lifting eyes are provided Check that the power rat...

Page 19: ...This should be factory set and not need to be done Fill oil tank to 2 3 level with your company recommended food safe oil WARNING DO NOT USE ORDINARY VEGETABLE OIL FROM SHOP SHELVES IN THE DIVIDER THI...

Page 20: ...ough will leave the out chute and roll down the infeed chute of the prover or use the locator mechanism if included 3 Correctly position the divider so that dough will leave the conveyor and drop down...

Page 21: ...the moulder is standing on a solid level floor 2 Correctly position the moulder under the chute so that the red magnet and switch are inline or use the locator if included 3 When the position is corr...

Page 22: ...anel PROVER MAIN ISOLATOR EMERGENCY STOP BUTTONS WARNING Except in an emergency do not halt the prover with dough in the carriers and leave it Dough will adhere to the pockets and may cause the prover...

Page 23: ...th dough in the carriers and leave it Dough will adhere to the pockets and may cause the machine to malfunction 2 ALWAYS CHECK THE POCKETS FOR ADHERING DOUGH AND REMOVE AS SOON AS POSSIBLE DO NOT WAIT...

Page 24: ...ang door 4 and check for fallen pieces of dough inside Brush rear of door and close 5 Brush out the hopper 5 and wipe clean the metalwork paying attention to the inner sides where dough can collect 6...

Page 25: ...s required 1 Open the front windows to access carriers 2 Hold the carrier body and pull the carrier pocket gently upwards to unclip Note that there are 4 pockets to a carrier and each one can be repla...

Page 26: ...any dough residue from the interior of the hopper Only use a plastic scraper 2 Smear the interior of the hopper with divider oil 3 Check the oil level is correct refill if required Then run the divide...

Page 27: ...e pressure board while cleaning takes place 4 Remove any dough residue and brush exposed parts 5 Scrape and wipe down the belt Only use a plastic scraper 6 Remove any dough residue from the conveyor m...

Page 28: ...nd hot water 4 Clean the exterior of the divider as necessary working from top to bottom 5 Swab dry with disposable tissue UNDER CONVEYOR COLLECTION BOX 1 Brush the chute debris into the collection bo...

Page 29: ...NLY BE CARRIED OUT BY FULLY TRAINED PERSONNEL WARNING ISOLATE DIVIDER FROM MAINS SUPPLY 1 Scrub wheels with a small nylon cleaning brush or scouring pad and hot water sterilising solution 2 Clean enti...

Page 30: ...machine away from the prover 2 Scrape off any dough residue 5 Raise front hinged cover 2 6 Lift out curling chain 3 and shake off any dough residue then brush with a stiff nylon brush DO NOT WASH 7 R...

Page 31: ...th by turning wheel 6 Push pressure board 7 towards the main body and then withdraw 16 Wash board in sterilising solution and hot water then dry well and replace 17 Scrape dough belt 8 with a plastic...

Page 32: ...previous section 2 Remove side and back panels placing screws in a safe place 3 Brush down framework where accessible to remove excess flour and dough 4 Wipe down with a damp cloth and sterilising flu...

Page 33: ...Don t use steel scrapers and poisonous chemicals or soap for cleaning purposes WEEKLY Outer sides should be cleaned by a wet cloth Scrape and scrub wheels clean as needed DANGER Cleaning operations s...

Page 34: ...machine operates continuously AUTO Led is off Starts the prover in auto mode No movement will happen until dough passes the sensor on the chute 2 Manual mode Auto mode selection 3 UV Controls the ultr...

Page 35: ...green button on divider and adjust weights as instructed in the divider manual 8 When satisfied with the dough weights allow the dough to enter the rounder The prover will move to the next carrier ev...

Page 36: ...R OPERATION TO ENSURE AN EVEN FLOW ONLY USE CLEAN DRY FLOUR DUSTER LOCATION OPEN LID AND FILL WITH DRY FLOUR THEN CLOSE THE LID TURN ON POWER WHEN REQUIRED ADJUST THE FLOW BY LOOSENING THE BLACK KNOB...

Page 37: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 35 9 0 ELECTRICAL INFORMATION SECTION FUSION COMPACT PRO NOTE This section may not be correct for your model Please contact MONO before using...

Page 38: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 36 THIS INFORMATION IS NOT AVAILABLE AT THE MOMENT INDIVIDUAL WIRING DIAGRAMS ARE AVAILABLE FOR THE DIVIDER AND THE ROUNDER LATER IN THIS MANUAL...

Page 39: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 37 FULL OPERATING AND MAINTENANCE MANUAL FOR THE FUSION BREADPLANT DIVIDER DIVIDER FULL INSTRUCTIONS SECTION 2...

Page 40: ...L COULD AFFECT THE WARRANTY and SAFETY OF THIS MACHINE WARNING DIVIDER OIL O NOT USE ORDINARY VEGETABLE OIL FROM SHOP SHELVES IN THE DIVIDER THIS WILL FORM A GUM LIKE RESIDUE CAUSING STICKING AND POSS...

Page 41: ...L DIMENSIONS 41 3 0 SPECIFICATIONS 41 4 0 SAFETY 42 5 0 INSTALLATION 43 6 0 ISOLATION 45 7 0 CLEANING INSTRUCTIONS 46 Daily 46 Weekly 50 8 0 OPERATING 51 9 0 MAINTENANCE 54 10 0 TROUBLESHOOTING 56 11...

Page 42: ...apacity hopper simple controls and adjustments The in line discharge gives a very compact machine The dough divider has the capacity to accurately scale dough pieces Between 8oz 250g and 36 oz 1000g N...

Page 43: ...GENERAL DIMENSIONS Height 1580mm Depth 1065mm inc conveyor 1400mm Width 670mm 3 0 SPECIFICATIONS Total power 3 2kW three phase N E 415v 50Hz Capacity Accurately scaled dough pieces between 250g and 1...

Page 44: ...ructions in this manual are required to operate this machine safely The owner and the operator are responsible for operating this machine safely DO NOT TRY TO DISABLE ANY SAFETY DEVICES THEY ARE FITTE...

Page 45: ...llet To lift with a crane lifting eyes are provided Check that the power rating on the serial number plate matches the supply that the machine is to be connect Check machine after installation to ensu...

Page 46: ...GETABLE OIL FROM SHOP SHELVES IN THE DIVIDER THIS WILL FORM A GUM LIKE RESIDUE CAUSING STICKING AND POSSIBLE DAMAGE TO THE MACHINE MONO RECOMMENDS THE USE OF CRODA SUPER WUNDROL AVAILABLE FROM MONO PA...

Page 47: ...A21 14 04 21 45 6 0 ISOLATION TO STOP THE DOUGH DIVIDER IN AN EMERGENCY Switch off at the PLANT MAIN ISOLATOR or use plant EMERGENCY BUTTON OR EMERGENCY STOP BUTTON TWIST TO RELEASE DIVIDER EMERGENCY...

Page 48: ...ND KEEP CLEANING FLUIDS AWAY FROM ELECTRICAL SWITCHES 1 Remove the dough residue from interior of the hopper Only use plastic scraper 2 Smear interior of the hopper with divider oil 3 Check oil level...

Page 49: ...NING DO NOT USE ORDINARY VEGETABLE OIL FROM SHOP SHELVES IN THE DIVIDER THIS WILL FORM A GUM LIKE RESIDUE CAUSING STICKING AND POSSIBLE DAMAGE TO THE MACHINE MONO RECOMMENDS THE USE OF CRODA SUPER WUN...

Page 50: ...ssure board while cleaning takes place 4 Remove any dough residue and brush exposed parts 5 Scrape and wipe down the belt Only use a plastic scraper 6 Remove any dough residue from the conveyor metal...

Page 51: ...solution and hot water 4 Clean the exterior of the divider as necessary working from top to bottom 5 Swab dry with disposable tissue UNDER CONVEYOR COLLECTION BOX 1 Brush the chute debris into the col...

Page 52: ...SHOULD ONLY BE CARRIED OUT BY FULLY TRAINED PERSONNEL WARNING ISOLATE MACHINE FROM MAINS SUPPLY 1 Scrub wheels with a small nylon cleaning brush or scouring pad and hot water sterilising solution 2 C...

Page 53: ...Check that the hopper is clear of objects and Smear interior with divider oil WARNING DO NOT USE ORDINARY VEGETABLE OIL FROM SHOP SHELVES IN THE DIVIDER THIS WILL FORM A GUM LIKE RESIDUE CAUSING STICK...

Page 54: ...the setting and is not an indicator of weight size etc REPLACE CLEAN DOUGH INTO THE HOPPER DO NOT PUT BACK ON CONVEYOR Normally the first six dough pieces are put back into the hopper as weight consis...

Page 55: ...STER OPERATION TO ENSURE AN EVEN FLOW ONLY USE CLEAN DRY FLOUR DUSTER LOCATION OPEN LID AND FILL WITH DRY FLOUR THEN CLOSE THE LID TURN ON POWER WHEN REQUIRED ADJUST THE FLOW BY LOOSENING THE BLACK KN...

Page 56: ...ustment Conveyor belt should be no tighter than necessary to eliminate slippage Over tensioning can lead to belt and or bearing failure The belt should be adjusted by means of the adjustment tensionin...

Page 57: ...Plant Rev A21 14 04 21 55 Chain greasing Open the side panels Remove 2 fixing screws each side and swing open Check that the main drive and weight adjusting chains are clean and greased MAIN DRIVE CHA...

Page 58: ...ntermediate prover is correctly connected Check all safety switches are operating hopper closed etc Check a red stop button is not depressed Turn to release and that stop circuit reset button 8 has be...

Page 59: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 57 THE FOLLOWING SHOULD ONLY BE USED BY TRAINED SERVICE ENGINEERS...

Page 60: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 58...

Page 61: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 59...

Page 62: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 60...

Page 63: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 61...

Page 64: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 62 YASKAWA INVERTER DEFAULT SETTINGS...

Page 65: ...e Customer Service Department quoting the machine serial number on the silver information plate of the machine and on the front cover of this manual SPARES and OVERSEAS SUPPORT Queensway Swansea West...

Page 66: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 64 12 0 ELECTRICAL INFORMATION NOTE Due to continual improvements this section may not be correct for your model Please contact MONO before using...

Page 67: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 65 ELECTRICAL DISTRIBUTION...

Page 68: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 66 CONTROL CIRCUIT...

Page 69: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 67 EMERGENCY STOP MONITORING CIRCUIT HOPPER SAFETY SWITCH OFFTAKE SWITCH...

Page 70: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 68 MOULDER FULL OPERATING AND MAINTENANCE MANUAL FOR THE BREADPLANT METRO MOULDER SECTION 3...

Page 71: ...1 69 Ensure the moulder is set up and adequate tins and trays are available before starting the breadplant IF YOU ENCOUNTER ANY ISSUE WITH THIS EQUIPMENT THAT YOU HAVE NOT BEEN TRAINED FOR YOU MUST CO...

Page 72: ...SAFETY 73 5 0 INSTALLATION 74 6 0 ISOLATION 75 7 0 CLEANING 76 Daily 76 Weekly 78 8 0 OPERATING INSTRUCTIONS 79 How the Metro moulds dough pieces 79 Operating the Metro moulder 80 Starting the Metro 8...

Page 73: ...versatile machine which has a maximum output of 1200 dough pieces an hour The double sheeting rolls give a gentle two stage reduction of the dough and two curling chains give greatly improved consiste...

Page 74: ...d Plant Rev A21 14 04 21 72 3 0 SPECIFICATIONS CAPACITY Dough piece weight range 56grms to 1 8Kg 2oz to 4lbs OUTPUT Up to 1200 pieces per hour POWER 0 75kW 3 phase and neutral WEIGHT 230kg 507lbs NOIS...

Page 75: ...or screws unless protected by a safety switch 10 No loose clothing or jewellery to be worn while operating the machine 11 Switch off power at the mains isolator when machine is not in use and before...

Page 76: ...conveyor belt runs in the right direction see direction of arrow below This should be done by inching the motor If the motor rotation is incorrect transpose any two wires of the three phase carrying w...

Page 77: ...ad Plant Rev A21 14 04 21 75 6 0 ISOLATION In an emergency switch off the machine at the prover isolator or at the emergency stop button shown below To release stop button after use twist and release...

Page 78: ...ll machine away from the prover 2 Scrape off any dough residue 5 Raise front hinged cover 2 6 Lift out curling chain 3 and shake off any dough residue then brush with a stiff nylon brush DO NOT WASH 7...

Page 79: ...in a sterilising solution and hot water 15 Open dough guides to maximum width by turning wheel 6 Push pressure board 7 towards the main body then withdraw 16 Wash board in sterilising solution and ho...

Page 80: ...COMMENCING ANY CLEANING SUPPLY BEFORE COMMENCING CLEANING 1 Follow the daily cleaning instructions 1 14 in previous section 2 Remove side and back panels placing screws in a safe place 3 Brush down fr...

Page 81: ...dough This is carried along the off take conveyor C to the curling chain D The curling chain then picks up the leading edge of the dough sheet and forms a curled roll of dough This is then carried to...

Page 82: ...width move cheeks 15 to required width b Sheeting gap move lever 16 c Side guides position turn wheel 6 to adjust pressure board width d Moulding pressure turn handle 17 to adjust pressure board heigh...

Page 83: ...ested settings c SIDE GUIDES ADJUSTMENT 1 Turn wheel 6 to required setting See chart for suggested settings d MOULDING PRESSURE ADJUSTMENT 1 The pressure board height is adjusted by turning the adjust...

Page 84: ...a prover make sure that the Metro is in the correct position with the hopper Do not allow dough pieces to skin as this will result in the dough pieces catching each other up doubling and could cause...

Page 85: ...op button released twist to release Are all covers and doors closed When used with a prover is machine in the correct position under the conveyor DOUGH PIECES DOUBLE UP Dough has been allowed to skin...

Page 86: ...tomer Service Department quoting the machine serial number on the silver information plate of the machine and on the front cover of this manual MONO Queensway Swansea West Industrial Estate Swansea SA...

Page 87: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 85...

Page 88: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 86 11 0 ELECTRICAL INFORMATION...

Page 89: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 87...

Page 90: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 88...

Page 91: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 89 ROUNDER FULL OPERATING AND MAINTENANCE MANUAL FOR THE BREADPLANT CONICAL ROUNDER SECTION 4...

Page 92: ...5 0 INSTALLATION 94 6 0 ISOLATION 95 7 0 CLEANING 96 8 0 OPERATING CONTROLS 97 9 0 TROUBLESHOOTING 98 10 0 SPARES AND SERVICE 99 FOR SERVICE AND SPARES RING 01792 564044 11 0 MOULDER ELECTRICAL INFOR...

Page 93: ...dough pieces for the intermediate prover of the Mono Fusion Pro models Fed from the divider it forms perfectly rounded dough pieces with the help of a flour duster and gently blown air before passing...

Page 94: ...ant Rev A21 14 04 21 92 3 0 SPECIFICATIONS CAPACITY Dough piece weight range 100grms to 1200grms OUTPUT Up to 960 pieces per hour LENGTH OF ROUNDING TRACK 3 Metres POWER 0 55kW 220 380 VAC WEIGHT 205k...

Page 95: ...xed in place with bolts or screws unless protected by a safety switch 10 No loose clothing or jewellery to be worn while operating the machine 11 Switch off power at the mains isolator when machine is...

Page 96: ...rrect socket on the prover 4 Check the machine after installation to ensure the cone runs in the right direction see direction of arrow below This should be done by inching the motor This should have...

Page 97: ...ISOLATION In an emergency switch off the plant at the wall isolator the main isolator on the front of the rounder or the emergency stop button shown below EMERGENCY STOP BUTTON To release stop button...

Page 98: ...t use steel scrapers and poisonous chemicals or soap for cleaning purposes Every week Outer sides should be cleaned by a wet cloth Scrape and scrub wheels clean as needed DANGER Cleaning operations s...

Page 99: ...L FLOUR DUSTER Open lid and insert dry flour as required Close lid This allows the rounding speed to be adjusted to match other machines if needed Push to operate Turn and release to reset MOVE DUSTER...

Page 100: ...nt of malfunctioning which still persists after the suggested action has been taken PROBLEM POSSIBLE CAUSE SOLUTION When the start button is pressed the machine does not start Flour lid is open Emerge...

Page 101: ...tomer Service Department quoting the machine serial number on the silver information plate of the machine and on the front cover of this manual MONO Queensway Swansea West Industrial Estate Swansea SA...

Page 102: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 100 11 0 ELECTRICAL INFORMATION...

Page 103: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 101...

Page 104: ...Fusion Compact Pro Bread Plant Rev A21 14 04 21 102...

Page 105: ......

Page 106: ...92 561016 DISPOSAL CARE SHOULD BE TAKEN WHEN THE MACHINE COMES TO THE END OF ITS WORKING LIFE ALL PARTS SHOULD BE DISPOSED OF IN THE APPROPRIATE PLACE EITHER BY RECYCLING OR OTHER MEANS OF DISPOSAL TH...

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