Moffat VM404 User manual
SERVICE MANUAL
Versatile 2 Moulder with Light Guard Mouth © Copyright Moffat Ltd. 28 June 2022.
300166 Amdt 9
VERSATILE 2 MOULDER
with Lightspeed Guard Mouth
VM404
VM704
All Installation and Service Repair work must be carried out by Qualified Persons Only.
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Versatile 2 Moulder with Light Guard Mouth © Copyright Moffat Ltd. 28 June 2022.
300166 Amdt 9
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CONTENTS
Versatile 2 Moulder with Light Guard Mouth © Copyright Moffat Ltd. 28 June 2022.
300166 Amdt 9
This manual is designed to take an in depth look at the Moffat Versatile 2 Moulder for the purpose of making the units more understandable
to service technicians.
There are settings explained in this manual that should never require adjustment, but for completeness and in special cases where these
settings are required to be changed, this manual gives a full explanation of how to change these settings and what the effects of these
changes will be.
Section Page No.
2.1 Commissioning
2.2 Rating Plate Location
4.1 Cleaning
4.2 Routine Procedures
6.1 Fault Diagnosis
6.2 Access
6.3 Replacement
6.4 Adjustment / Calibration
VM404 / VM704 Wiring Schematic - 400 - 415V
VM404 / VM704 Wiring Schematic - 208 - 220V (Canada Only)
8
8.1 Moulder Main Assembly
8.2 Moulder Left Hand Side
8.3 Moulder Right Hand Side
8.4 Guard and Roller Assembly
8.5 Emergency Stop - Push Button
8.6 Rear of Moulder
8.7 Four Piece Blades Assy
8.8 Sheeting Rollers and Upper Scraper
8.9 Lower Scraper
8.10 Bap Flap (VM-704 Only)
8.11 Top Belt Roller (VM404 and VM704)
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1. SPECIFICATIONS
Versatile 2 Moulder with Light Guard Mouth © Copyright Moffat Ltd. 28 June 2022.
300166 Amdt 9
MODEL: VERSATILE 2 MOULDER
ELECTRICAL SUPPLY SPECIFICATION
Australia / New Zealand;
400 - 415 Volt, 3P + E, 50Hz, 1.0kW.
Canada;
208 - 220 Volt, 3P + E, 60Hz, 1.0kW.
POWER CORD / PLUG SPECIFICATIONS
Australia / New Zealand;
Supplied with fitted power cord, 56PA410 (4 pin, 3P + E, 10 Amp)
plug.
Canada;
Supplied with fitted power cord, SOOW, 4C, 16AWG, NEMA L15
20P (250V, 20A, 4 Pin) Plug.
PRODUCT CAPABILITY
Recommended weight range: 30-1200 grams.
OVERALL CONSTRUCTION
Galvanised steel main body, stainless steel finish.
Fibreglass mouldings.
Curling Chain, stainless steel construction (removable for
cleaning).
Sheeting Rollers, non stick PVC material.
OPERATION
Light Beam Safety Guard.
Four piecing blades activated by front lever.
Loaf guides fitted with width adjustment lever.
Fully adjustable sheeting roller settings.
Operation and Emergency stop buttons front mounted.
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2. INSTALLATION
Versatile 2 Moulder with Light Guard Mouth © Copyright Moffat Ltd. 28 June 2022.
300166 Amdt 9
The following commissioning checks must be carried out before the
moulder is handed over for use, to ensure that the unit operates
correctly and the operator(s) understand correct operation.
Ensure that the moulder belts turn in the correct direction. If
incorrect then swap over two of the phases to the motor, to
give correct rotation
With the machine running, test the operation of the emergency
stop button. The machine must stop immediately.
Each operator must be instructed in the correct usage of the
machine.
Please consult the supplied Installation and Operation
Manual for full operation and safety information.
The rating plates for the Versatile Moulder are located at the rear of
the moulder as shown below, as viewed from the rear of the
appliance;
Primary Rating Plate - Inside of the left hand frame
Secondary Rating Plate - On the cross-rail at the rear of
the appliance.
Figure 2.2
All Installation and Service Repair work must be carried out by qualified persons only.
Primary Rating Plate Secondary Rating Plate
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3. OPERATION
Versatile 2 Moulder with Light Guard Mouth © Copyright Moffat Ltd. 28 June 2022.
300166 Amdt 9
NOTE: A full user’s Installation and Operation Manual is supplied with the product and can be used for further referencing of
installation, operation and service information.
NOTE: For detailed instructions on the operation of the
Versatile 2 Moulder, refer to the Installation and
Operation manual supplied with the equipment.
Set sheeting roller gap to required product setting.
Set rear belt to required product setting.
If using the optional splitter attachment, the width guide
attachment should now be lowered into the machine, and
set to the desired width.
Pull out the catch tray.
For small dough pieces, lower guide roller assembly into
place. This assembly keeps dough pieces centred during
the moulding process. Mainly for 4 piecing of bread and
sandwich loaves.
Press the green START button.
Feed dough into the roller assembly.
Follow the recommended workplace procedures for the
desired product.
Observe the action of the dough pieces under the curling
chain. Dough should curl upwards and not deviate to the
sides.
Check the resultant end product against workplace standard
for shape, size and consistency.
Repeat the process.
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4. MAINTENANCE
Versatile 2 Moulder with Light Guard Mouth © Copyright Moffat Ltd. 28 June 2022.
300166 Amdt 9
Brush off all external surfaces, working from top to bottom.
Clean the mouth assembly with a damp cloth.
Open the moulder feed mouth.
Open the sheeting rollers to maximum (15) and wipe down
with a damp cloth.
To remove curling chain, lift out the assembly.
Check for build up and wash if needed in warm water.
Check the rear belt for signs of old dough. Clean with a
plastic scraper if necessary and brush lightly.
NOTE: Never use a metal scraper to clean the rear belt.
Clean attachment arms and rollers with a plastic scraper
and damp cloth.
Brush flour dust from the electrical motor intake.
Clean splitter blades with a plastic scraper and a damp
cloth.
Re-assemble the machine.
DAILY
Clean machine as detailed in Section 4.1.
MONTHLY
Remove side panels and remove any old dough and flour
build up.
Brush the motor to remove any flour dust.
Check motor drive belt for any wear or stretching. Adjust or
replace as necessary.
YEARLY
Lubricate the drive chains.
ENSURE ALL ELECTRICAL POWER TO THE APPLIANCE IS SWITCHED ‘OFF’ BEFORE COMMENCING CLEANING.
THIS UNIT IS NOT WATERPROOF, DO NOT USE A WATER JET SPRAY TO CLEAN THE INTERIOR OR EXTERIOR OF THIS UNIT.
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5. FAULT FINDING GUIDE
Versatile 2 Moulder with Light Guard Mouth © Copyright Moffat Ltd. 28 June 2022.
300166 Amdt 9
Problem Possible Cause Remedy
THE MOULDER DOES NOT OPERATE /
START.
Not plugged in to socket at main switch.
The main switch is 'Off'.
Fuse or circuit breaker at the power board is
tripped.
Emergency stop button locked in down
position.
Emergency stop button faulty.
A microswitch or safety key switch has been
activated or is faulty.
Start switch faulty.
(Refer Fault Diagnosis 6.1.1).
Stop switch faulty.
(Refer Fault Diagnosis 6.1.1).
Contactor faulty.
(Refer Fault Diagnosis 6.1.1).
Motor overload faulty.
(Refer Fault Diagnosis 6.1.1).
Circuit Breaker tripped (Canada Only).
(Refer Fault Diagnosis 6.1.1).
Plug in and turn 'On' main switch.
Turn 'On' main switch.
Check for electrical fault.
Release by pulling firmly.
Replace the emergency stop button.
(Refer Service Section 6.3.11).
Check all switches (safety key switch, front guard
switch, rear guard switch).
Replace left hand lightspeed horn.
(Refer Service Section 6.3.10).
Replace right hand lightspeed horn.
(Refer Service Section 6.3.10).
Replace contactor.
(Refer Service Section 6.3.12).
Replace motor overload.
(Refer Service Section 6.3.12).
Check Circuit Breaker is switched ‘On’.
Check 24V Power tripping fault.
THE MOULDER STARTS AND THEN
STOPS.
Moulder overload has been activated.
Motor overload incorrectly set.
Motor overload faulty.
(Refer Fault Diagnosis 6.1.1 and 6.1.2).
Motor faulty.
(Refer Fault Diagnosis 6.1.2).
Motor Overload resets automatically after 10mins.
Set Motor overload to 2.0 A.
Replace motor overload.
(Refer Service Section 6.3.12).
Replace motor.
(Refer Service Section 6.3.2).
THE MOULDER BELTS OPERATE IN THE
WRONG DIRECTION.
Electrical phase rotation incorrect. Swap two phases to ensure belts rotate in the
correct direction.
CHAIN JUMPING NOISES. Broken idler gear tensioning spring.
Motor operating in wrong direction (phase
rotation incorrect).
Replace idler gear tensioning spring.
(Refer Service Section 6.3.4).
Swap two phases to ensure belt rotates in the
correct direction.
(Refer Service Section 6.3.1 and
Fig 6.3.1a).
THE MOULDER LABOURS UNDER LOAD /
DRIVE BELT SLIPPING.
Dough too stiff / tight.
Stretched or loose drive belts.
Review and adjust the dough consistency or
adjust the rear belt settings to a wider gap.
Re-tension or replace drive belts.
(Refer Service Section 6.3.1 & 6.4.3).
MOTOR OPERATES BUT BELTS DO NOT
TURN.
Machine has been started in the wrong
direction causing the chain to jump off the
sprockets.
Refit chain and check electrical phase rotation.
BELT EDGES FRAYING. Tracking of belts is incorrect. Adjust belt tracking.
(Refer Service Section 6.4.2).
DOUGH STICKING TO SHEETING
ROLLERS.
Scrapers out of alignment.
Scraper spring broken.
Check alignment of scrapers.
(Refer Service Section 6.4.5 & 6.4.6).
Replace scraper spring.
(Refer Service Section 6.3.8 & 6.3.9).
All Installation and Service Repair work must be carried out by Qualified Persons Only.
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6. SERVICE PROCEDURE
Versatile 2 Moulder with Light Guard Mouth © Copyright Moffat Ltd. 28 June 2022.
300166 Amdt 9
SECTION PAGE NO.
6.1.1 Moulder Does Not Operate ................................................................................................................................ 10
6.1.2 Moulder Starts Then Stops ................................................................................................................................ 10
6.2.1 Side Cover Panels ............................................................................................................................................. 11
6.2.2 Lightspeed Mouth Guard Assy............................................................................................................................ 11
6.2.3 Front Cover ...................................................................................................................................................... 11
6.3.1 Vee Belt ........................................................................................................................................................... 12
6.3.2 Motor............................................................................................................................................................... 12
6.3.3 Drive Pulley and Drive Chain.............................................................................................................................. 12
6.3.4 Right Hand Drive Chain ..................................................................................................................................... 13
6.3.5 Stop Bar Microswitch......................................................................................................................................... 13
6.3.6 Lightspeed Mouth Guard Microswitch ................................................................................................................. 14
6.3.7 Top Sheeting Roller Scraper .............................................................................................................................. 14
6.3.8 Bottom Sheeting Roller Scraper ......................................................................................................................... 15
6.3.9 Feeder Mouth Roller Scrapers............................................................................................................................ 15
6.3.10 Lightspeed Horns.............................................................................................................................................. 16
6.3.11 Emergency Stop Switch..................................................................................................................................... 16
6.3.12 Motor Contactor / Overload ............................................................................................................................... 17
6.4.1 Moulding Belt Tension....................................................................................................................................... 18
6.4.2 Moulding Belt Tracking...................................................................................................................................... 18
6.4.3 Drive Belt Tension............................................................................................................................................. 18
6.4.4 Microswitch Position - Adjusting......................................................................................................................... 18
6.4.5 Top Sheeting Roller Scraper Position.................................................................................................................. 19
6.4.6 Bottom Sheeting Roller Scraper Position............................................................................................................. 19
ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY QUALIFIED PERSONS ONLY.
ENSURE ALL ELECTRICAL POWER TO THE APPLIANCE IS SWITCHED ‘OFF’ BEFORE COMMENCING SERVICING.
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6. SERVICE PROCEDURE
Versatile 2 Moulder with Light Guard Mouth © Copyright Moffat Ltd. 28 June 2022.
300166 Amdt 9
6.1.1 MOULDER DOES NOT OPERATE 6.1.2 MOULDER STARTS THEN STOPS
Motor Faulty
With the motor running, check the current draw of each phase.
This should be approximately 1.1A. If the current draw is well in
excess of this then the motor may have stalled (check motor and
linkages) or else the motor is faulty.
Overload Faulty
The overload is set to trip at a current of 2.0A. If the current is less
than this, and the overload is repeatedly tripping, then the overload
is faulty - replace.
START Switch Faulty
The green START switch has normally open switch contacts. Check
that there is no continuity through the switch when it is not
depressed, and that there is continuity while the switch is depressed.
STOP Switch Faulty
The red STOP switch has normally closed switch contacts. Check
that there is continuity through the switch when it is not depressed,
and that there is no continuity while the switch is depressed.
Microswitch or Limit Switch Faulty
The microswitch(es) and limit switch have normally open switch
contacts. Check that there is continuity through the switch when it
is activated, and no continuity when it is de-activated.
Motor Overload Faulty
Check for continuity through terminals 95 and 96 of the motor
overload. If there is no continuity then the overload has tripped or
is faulty. Check also for continuity through terminals 1-2, 3-4, and
5-6. If there is no continuity then the overload is faulty.
Contactor Faulty
With the start switch held in check for voltage (415V ac) across
terminals A1 and A2 of the contactor. If there is voltage but the
contactor will not activate then the contactor is faulty - replace.
If there is no voltage to the contactor then check wiring.
Contact Breaker (Canada Only)
Check that the contact breaker protecting the 24V power supply is
switched ‘On’.
If the circuit breaker has tripped, check the 24V power supply for
fault.
Figure 6.1.2
Overload
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