Transcript
SOFT-SERVE AND FROZEN YOGHURT FREEZER SERVICE MANUAL (SERVICE MANUAL)
for MODEL: EFE 1500 Manual Number: V 001 - 17.05.2012
TABLE OF CONTENTS
1) 2) 3) 4) 5) 6) 7) 8) 9)
Expansion Valve Adjustment Refrigeration System Schematic Control Functions Air Adjustment Electrical System Troubleshooting (General, Inverter) Inverter Control by a Laptop Bacteria Troubleshooting Exploded Views
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1. EXPANSION VALVE ADJUSTMENT Adjust the pressure higher or lower by turning the expansion valve adjustment screw. Clockwise turns will raise the pressure and counterclockwise will lower the pressure.Bear in mind that In this model 360° turning is enough.
2. REFRIGIRATION SYSTEM SCHEMATIC
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3. CONTROL FUNCTIONS
Stop Machine operates keeping the temperature of the mix in the tankaround 4C. Therefore compressor runs at this mode if the temperature is not mentioned above.
Wash Machine operates cooling the mix in the tank and beater turns to blend the mix in the cylinder. Beater runs just because to take the mix out of the cylinder in a short time.
Standby Machine operates keeping the temperature of the mix in the tank and cylinder around 4C.
Soft&Hard Machine operates keeping the temperature of the mix in the tank around 4C. Moreover, it cools down the mix in the cylinder around -6C when beater turns. Machine checks the current in the beater motor by an inverter when the current is around 2.6Amp for soft mode 2.8 Amp for hard mode, it stops cooling in the cylinder. However, beater turns and cooling in cylinder starts if the motion sensor is activated by showing anything in front of them. This is done normally when ice-cream is needed to dispense for serving. Otherwise, inverter tracks the time for 5 minutes and then cooling in the cylinder starts and beater turns again. This goes on repeatedly. As it can be seen, soft and hard modes are for turning the mix into ice-cream to be served. When the temperature in the cylinder goes down the current need of the beater motor is increased. 4
4. AIR ADJUSTMENT The AERATION TUBE has two parts ― OUTER and INNER The OUTER has a large hole TOP and BOTTOM (These are constant) The INNER tube has 3 different size holes TOP and BOTTOM The INNER is turned inside the OUTER to select SMALL, MEDIUM or LARGE
TOP LARGE INNER
BOTTOM LARGE INNER
TOP MEDIUM INNER
BOTTOM MEDIUM INNER
TOP SMALL INNER
BOTTOM SMALL INNER
The selection of the correct INNER hole-size depends on the product that is run through the Soft-Serve Freezer and what amount of aeration is desired. The setting can be changed during operations by simply turning the INNER aeration tube to the desired size hole. The SMALL HOLE will increase air percentage in the Soft-Serve and yield higher overrun. The MEDIUM HOLE will result in an average air percentage and yield a medium overrun. The LARGE HOLE for will decrease the air percentage and yield a lower overrun. The LARGE HOLE setting may also be required for high-viscosity (thick) liquid mixes 5
5. ELECTRICAL SYSTEM
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6.TROUBLESHOOTING
6.1. General Troubleshooting
Problem
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Machine does not run
CAUSE
Solution
Burnt Fuse
Check&Replace.
Machine Unplugged
Check&Plug the Machine
Selector mode is wrong
Set the selector one of the soft-medium-hard modes
Compressor starts then stops Air Not circulating after few seconds without Air circulation restricted Machine fails to Cut-off when running on ice cream Too much air in cylinder modes(soft-medium-hard) No mix in Hopper(tank)or just froth Frozen water in Machine works but no ice spigot(piston) cream comes out of tap No enough sugar in mix
Clereances should be 50 cm. Clereances should be 50 cm. Open tap&take off 1/2 litre of ice cream Pour fresh mix All to thaw and take out 1 lt of mix/ice cream before starting Replace with proper mix
Too much sugar in mix
Replace with proper mix
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Machine runs but ice cream is too soft
Machine remained idle without dispensing ice cream Ice cream dispensed is too fast
Take out ice cream untill fresh mix is filled in cylinder Do not exceed the production shown in the capacity
Mix or ice cream comes out from below or above the closed tap/piston
Piston o-ring missing
Putt the o-ring on piston
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Piston with ruined o-ring
Replace the o-ring with a new one
Beater seal missing
Put the beater seal
Beater seal ruined
Replace the beater seal
Cylinder(s) empty
Add fresh mix
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Mix comes from union drain
Ice cream does not come out Too much air in cylinder(s) of central tap Ice cream frozen
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Ice cream comes out from front lid/spigot
Ice cream not increased much in volume(overrun)
O-ring missing or not placed properly Front knobs not tightened properly/evenly O-rings leaking
Add fresh mix Run the machine on cleaning mode so that frozen ice cream will be melt Place O-ring properly Tighten knobs evenlyand properly Check and Replace, if necessary O Rings of Pipe Tighten knobs evenly
Improper mix
Refill with proper mix(Proper fat&sugar)
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6.2.Inverter Troubleshooting
*Description of Terminals Troubleshooting inverter
SYMBOL R\L1(L) S\L2 T / L3 ( N ) P1 BR P1/ P U / T1 V / T2 W / T3
Description of Terminals of Troubleshooting Inverter Descriptions of main circuit terminals Description Main power input Single-phase: L/N Braking resistor or connecting terminal: Used in cases where the inverter frequently disconnects due to large load inertia or short deceleration time (refer to specifications of braking resistor) DC reactor connecting terminals (bridging connection P1 – P must be removed for connecting an DC reactor)
For 220V:1HP
Inverter outputs
Descriptions of SYNPLUS control circuit terminals SYMBOL R2A R2B R1C R1B R1A 10V AIN 24V COM FM+ SYMBOL
Description Multifunctional terminal – Normal open Common contact
ALARM BUZZER
L
Normal close contact
HOPPER DIGITAL THERMOSTAT
Normal open contact
CYLINDER VALVE
Frequency knob (VR = Potentiometer ), when operating with optional LED keypad power source terminal (pin 3)
Multifunctional output terminals LEVEL SENSOR,ALARM BUZZER
Analog frequency signal input terminal or multifunction input terminals S7 (H level:>8V, L level:<2V, PNP only) Common contact for S1~S5 (S6, S7)in PNP (Source) input. Short-circuit pin 2 and pin 3 (refer to SYNPLUS wiring diagram) of SW1 when used PNP input
Rotary switch,optical sensor
Common contact and analog input /output signal for S1~S5in NPN (Sink) input. Short-circuit pin 2 and pin 3 (refer to SYNPLUS wiring diagram) of SW1 when used NPN input
optical sensor,ssr,alarm buzzer
The positive analog output for multifunction (refer to 8-00 description), the signal for output terminal is 0-10VDC (below 2mA).
SSR
LEVEL SENSOR
Function Description
S1 S2
Wash-rotary switch 1
S3
Stand by-rotary switch 2
S4
Soft-rotary switch 3
S5
Hard-rotary switch 4
S6
optical sensor
Multifunction input terminals(refer to 5-00 ~ 5-04 description) (S5 = Encoder input terminal for integrated PLC functionality, the Encoder voltage range: 19.2V~24.7V)
Multifunction input terminals ( Digital terminal H level:>8V, L level:<2V, PNP only) o r analog input terminal A I 2 ( 0 ~ 1 0 V d c / 4 ~ 2 0 m A ) ( refer to 5-05 description)
Descriptions of SW function
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*Error display and remedy *Error which cannot recovered manually Display
Errors which can not be recovered manually Error Cause
Remendy
CPF
PROGRAM PROBLEM
External noise interference
Connect a parallel RC burst absorber across the magnetizing coil of the magnetic contactor that causes interference
EPR
EEPROM problem
Faulty EEPROM
Replace EEPROM
-OV-
Voltage too high during stop
Detection circuit malfunction
Voltage too low during stop
1. Power voltage too low 2. Restraining resistor or fuse burnt out. 3. Detection circuit malfunctions
Send the inverter back for repairing 1. Check if the power voltage was correct or not 2. Replace the restraining resistor or the fuse 3. Send the inverter back for
The inverter is overheated during stop
1. Detection circuit malfunctions 2. Ambient temperature too high or bad ventilation
1. Send the inverter back for repairing 2. Improve ventilation conditions
-LV-
OH
Display
Errors which can be recovered manually and automatically Error Cause
Remendy
OC-S
Over current at start
1. the motor wind and enclosure short circuit 2. the motor contacts and earth short circuit 3. the IGBT module ruined
OC-D
Over-current at deceleration
The preset deceleration time is too short.
Set a longer deceleration time
Over-current at acceleration
1. Acceleration time too short 2. The capacity of the motor higher than the capacity of the inverter 3. Short circuit between the motor coil and the shell 4. Short circuit between motor wiring and earth 5. IGBT module damaged
1. Set a longer acceleration time 2. Replace a inverter with the same capacity as that of the motor 3. Check the motor 4. Check the wiring 5. Replace the IGBT module
1. Transient load change 2. Transient power change
1.Increase the capacity of the inverter 2.Rerun parameter auto tuning (0-06 = 1) 3. Reduce stator resistance (14-0) if the above remedies are helpless
OC-A
OC-C
Over-current at fixed speed
1.inspect the motor 2.inspect the wire 3.replace the transistor module
OV-C
Voltage too high during operation/ deceleration
1. Deceleration time setting too short or large load inertia 2. Power voltage varies widely
1. Set a longer deceleration time 2. Add a brake resistor or brake module 3. Add a reactor at the power input side 4. Increase inverter capacity
Err4
Illegal interrupt of CPU
Outside noise interference
Send back to repair if it happens many times
Over speed during operating
1. Motor load too big or Inverter capacity too small 2. Motor parameter error (vector mode) 3. The gain is too big during vector mode operating 4. The Current detect circuit fault
1. Increase acceleration / deceleration time (3-02/3-03) 2. Input correct motor Parameter 3.Change stator Resistance gain and Rotator resistance gain (14-0/14-1), suggest that decrease 50~100, until 0 4. Send back to SMACH.
OVSP
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Errors which can be recovered manually Cause
Display
Error
OC
Over-current duri ng s top
1. Detecti on ci rcui t mal functi ons 2. Ba d connecti on for CT s i gnal cabl e
1.Check the noi s e between Power l i ne a nd motor l i ne 2.Send the i nverter ba ck for repai ri ng
OL1
Motor overl oa d
1. Hea vy l oad 2. I nappropri a te s etti ngs of 0-02, 9-08~11
1. Increa s e the motor capaci ty 2. s et 0-02, 9-08~11 properl y
OL2
Inverter overl oa d
Heavy Load
Increa s e the i nverter capaci ty
OL3
Over torque
1. Hea vy Load 2. Ins uffi ci ent s etti ngs of 9-14, 9-15
1. Increa s e the i nverter capaci ty 2. s et 9-14, 9-15 properl y
LV-C
Vol ta ge too l ow duri ng opera ti on
1. Power vol ta ge too l ow 2. Power vol ta ge vari es wi del y
OH-C
Heats i nk temperature too Hi gh duri ng opera ti on
1. Hea vy l oad 2. Ambi ent tempera ture too hi gh or ba d venti l a ti on
Remendy
1. Improve power qual i ty or i ncrea s e the va l ue of 2-01 2. Set a l onger a ccel erati on ti me 3. Increas e i nverter ca pa ci tor 4. Add a reactor a t the power i nput s i de 1. Check i f there a re any probl ems wi th the l oad 2. Increas e i nverter capaci ty 3. Improve venti l ati on condi ti ons
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*Special Condition Special conditions Display
Error
DESCRIPTION
STP0
Zero s peed s top
Ha ppened when pres et frequency <0.1Hz
Fai l to s tart di rectl y
1. If the i nverter i s s et a s external termi na l control mode (1-00=1) a nd di rect s ta rt i s di s a bl ed (2-04=0001), the i nverter ca nnot be s ta rted a nd wi l l fl a s h STP1 when operati on swi tch turned to ON a fter a ppl yi ng power (refer to des cri pti ons of 2-04). 2. Di rect s ta rt i s pos si bl e when 2-04=0001.
STP2
Keypad emergency s top
1. If the i nverter i s set as externa l control mode (1-00=0001) a nd Stop key i s ena bl ed (1-03=0000), the i nverter wi l l s top a ccordi ng to the s etti ng of 1-05 when Stop key i s pres s ed. STP2 fl a s hes after s top. Turn the operati on s wi tch to OFF a nd then ON a ga i n to res ta rt the i nverter. 2. If the i nverter i s i n communi cati on mode a nd Stop key i s ena bl ed (103=0000), the i nverter wi l l s top i n the way s et by 1-05 when Stop key i s pres s ed duri ng opera ti on a nd then fl as hes STP2. The PC ha s to s end a Stop command then a Run comma nd to the i nverter for i t to be res tarted. 3. Stop key cannot perform emergency s top when 1-03=0001
E.S.
Externa l emergency s top
The i nverter wi l l ra mp s top a nd then fl a s h E.S., when i nput externa l emergency s top s i gnal vi a the mul ti functi ona l i nput termi na l (refer to des cri pti ons of 5-00~5-06).
b.b.
External ba s e bl ock
The i nverter s tops i mmedi atel y a nd then fl as hes b.b., when external ba se bl ock i s i nput through the mul ti functi ona l i nput termi na l (refer to des cri pti ons of 5-00~5-06).
ATER
Auto-tuni ng faul ts
1. Motor da ta error res ul ti ng i n for a uto-tuni ng fa i l ure 2. Stop the i nverter emergentl y duri ng Auto-tuni ng
PDER
PID feedback l oss
PID feedba ck l os s detect
STP1
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*Operation Errors Operation errors Cause
Display
Error
LOC
Pa ra meter a nd frequency revers e a l rea dy locked
1.Attempt to modi fy frequency /pa ra meter whil e 3-17>0000 2.Attempt to revers e whil e 1-02=0001
1.Set 3-17=0000 2. Set 1-02=0000
Key opera ti on error
1.Pres s _ or _whi l e 1-06>0 or runni ng a t pres et s peed. 2.Attempt to modi fy the pa ra meter ca n not be modi fied duri ng opera tion (refer to the pa ra meter l i s t).
1.The _ or_ i s a va i la bl e for modifyi ng the pa ra meter only when 1-06=0 2.Modify the pa ra meter whi le STOP
Err2
Pa ra meter s etti ng error
1. 3-01in the ra nge of 3-13 ± 3-16 or 3-14 ± 3-16or 3-15 ± 3-16 2. 3-00≤3-01 3.The s etting error a s performi ng Auto tuning(e.g. 1-00 ≠ 0_1-06 ≠ 0 )
1.Modify 3-13~3-15or 3-16 2. 3-00>3-01Set 1-00=0, 106=0 during Auto tuni ng
Err5
Modi fi ca ti on of pa ra meter is not a va i la ble in communi ca ti on
1.Is s ue a control comma nd duri ng communica ti on di s a bled 2.Modi fy the function 13-1~13-4 during communi ca tion
1.Is s ue ena bl e comma nd before communica ti on 2.Set the very pa ra meter of thefunctionbefore communica ti on
Err6
Communi ca ti on fa i l ed
1.Wiri ng error 2 .Communi ca ti on pa ra meter s etti ng error. 3.Sum-check error 4.Incorrect communi ca ti on protocol
1.Check ha rdwa rea nd wi ri ng 2.Check Functi on 13-1~13-4
Err7
Pa ra meter confli ct
1.Attempt to modi fy the function 15-0 or 15-7 2.Vol ta ge a nd current detecti on ci rcui t i s a bnorma l
If Res et i nverter i s not a va i l a ble, pl ea s e s end the i nverter ba ck for repa i r
Err8
Fa ctory s etti ng error
When PLC i s Running, Perform fa ctory s etti ng
Pl ea s e perform fa ctory s etti ng before PLC s tops .
EPr1
Pa ra meter s etti ng error copy uni t fa i l ed
1.Set 3-18=1.2 wi thout connecti ng copy unit. 2. Copy uni t fa i led.
1.Modify 3-18 2.Repl a ce copy uni t
EPr2
Pa ra meter not ma tch
Copy the pa ra meter to i nverter to veri fy the pa ra meter i s not ma tch.
1.Rewri te a ga i n 2.Repl a ce copy uni t
Err1
Remendy
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*General Troubleshooting of Inverter General troubleshooting Checking point
Status
Is power a ppl i ed to L1(L), L2, a nd L3(N) termi na l s (is the cha rging i ndi ca tor l i t)?
Remedy • Is the power a ppl ied? • Turn the power OFF a nd then ON a ga i n. • Ma ke s ure the power vol ta ge i s correct. • Ma ke s ure s crews a re s ecured fi rmly.
Are there volta ge a cros s the output termi na l T1, T2, a nd T3? • Turn the power OFF a nd then ON a ga in. Motor ca n run
not
Motor runs invers el y
The motor s peed ca n not be regul a ted. Motor runni ng s peed too hi gh or too l ow
Is overl oa d ca us ing the motor bl ocked? Are there a ny a bnorma l iti es i n the i nverter? Is forwa rd or revers e runni ng comma nd i s s ued?
• Reduce the loa d to let the motor runni ng. • See error des cri ptions to check wi ri ng a nd correct if neces s a ry.
Ha s a na log frequency s i gna l been input?
• Is a na l og frequency i nput s i gna l wiri ng correct? • Is volta ge of frequency i nput correct?
Is opera ti on mode s etting correct?
• Opera te opera ti ons through the di gita l pa nel.
Are wi ri ng for output termi na l s T1, T2, a nd T3 correct?
• Wiri ng mus t ma tch U, V, a nd W termi na l s of the motor.
Are wi ri ng for forwa rd a nd revers e s i gna l s correct?
• Check wiri ng a re correct if neces s a ry.
Are wi ri ng for a na log frequency i nputs correct?
• Check wiri ng a re correct if neces s a ry.
Is the s etting of opera tion mode correct?
• Check the opera ti on mode of the opera tor.
Is the l oa d too hea vy?
• Reduce the loa d.
Are s peci fi ca tions of the motor (pol es , volta ge…) correct?
• Confi rm the motor’s s peci fi ca tions.
Is the gea r ra ti o correct?
• Confi rm the gea r ra ti o.
Is the s etting of the hi ghes t output frequency correct?
• Confi rm the hi ghes t output frequency.
Is the l oa d too hea vy?
• Reduce the loa d.
Does the l oa d va ry l a rgel y?
• Mi nimi ze the va ri a ti on of the l oa d. • Increa s e ca pa citi es of the inverter a nd the motor.
Is the i nput power l a ck of pha s e?
• Add a n AC rea ctor a t the power i nput s i de if us ing s ingl e-pha s e power. • Check wi ri ng if usi ng three-pha s e power.
Motor s peed va ries unus ua l ly
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*Quick Troubleshooting of Inverter
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InverterFault
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Inverterfault
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7. INVERTER CONTROL BY A LAPTOP Inverter settings can be changed by the program named SYNPLUSand to connect to inverter over a laptop RS232 cable is needed. Then follow the instructions to change settings.
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8.BACTERIA BACTERIA TROUBLESHOOTING In food industry cleaning and sanitizing are very important in terms of human health. Lack of them results in high bacteria counts when a sampling is taken by a sanitarian.Bacteria counts should not exceed the following figures.
Therefore in a daily basis all machine achine parts which are subjected to the mix or ice-cream ice cream must be cleaned by using proper brushes and sanitized then mounted again. In mounting process especially for O-ring O ring suitable oil must be used. Below there is information about the sanitizer.
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Moreover, the ice-cream cream mix in the hopper must be kept around 4C. This is the best temperature for the bacteria count the least. And if the temperature of the mix poured into the hopper is around room temperature It must take max. 140 minutes to reach the temperature around 4C.To 4C. control the hopper temperature, remove the left side panel and check the thermostat as seen in the photo below. The thermostat which is closed to inverter must show around -2C(this (this is the average temperature of antifreeze which which is in a tank below the hopper) so this means the mix is around +4C in the tank(hopper). 25
9.EXPLODED VIEWS
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