Smach EFE 1500, EFE 2500P Service Manual

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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) Expansion Valve Adjustment

2) Refrigeration System Schematic

3) Control Functions

4) Air Adjustment

5) Electrical System

6) Troubleshooting (General, Inverter)

7) Inverter Control by a Laptop

8) Bacteria Troubleshooting

9) Exploded Views

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

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. 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

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

TOP LARGE INNER TOP MEDIUM INNER TOP SMALL INNER

BOTTOM LARGE INNER BOTTOM MEDIUM INNER

BOTTOM SMALL INNER

5. ELECTRICAL SYSTEM

6.TROUBLESHOOTING

6.1. General

Troubleshooting

Problem CAUSE Solution

1 Machine does not run

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

after few seconds without

Air Not circulating Clereances should be 50 cm.

Machine fails to Cut-off when running on ice cream modes(soft-medium-hard)

Air circulation restricted Clereances should be 50 cm. Too much air in cylinder Open tap&take off 1/2 litre of ice cream

No mix in Hopper(tank)or

just froth

Pour fresh mix

Machine works but no ice cream comes out of tap

Frozen water in

spigot(piston)

All to thaw and take out 1 lt of mix/ice cream

before starting

No enough sugar in mix Replace with proper mix

Machine runs but ice cream is too soft

Too much sugar in mix Replace with proper mix Machine remained idle

without dispensing ice cream

Take out ice cream untill fresh mix is filled in

cylinder

Ice cream dispensed is too

fast

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 Piston with ruined o-ring Replace the o-ring with a new one

7 Mix comes from union drain

Beater seal missing Put the beater seal Beater seal ruined Replace the beater seal

Ice cream does not come out

of central tap

Cylinder(s) empty Add fresh mix Too much air in cylinder(s) Add fresh mix Ice cream frozen

Run the machine on cleaning mode so that

frozen ice

cream will be melt

Ice cream comes out from front lid/spigot

O-ring missing or not placed

properly

Place O-ring properly

Front knobs not tightened

properly/evenly

Tighten knobs evenlyand properly

Ice cream not increased much in volume(overrun)

O-rings leaking

Check and Replace, if necessary O Rings of

Pipe

Tighten knobs evenly

Improper mix Refill with proper mix(Proper fat&sugar)

6.2.Inverter Troubleshooting

*Description of Terminals Troubleshooting inverter

SYMBOL R\L1(L) S\L2 T / L3 ( N ) P1

P1/ P U / T1 V / T2 W / T3

SYMBOL R2A R2B R1C

Common conta ct

R1B

Norma l clos e conta ct

R1A

Norma l open conta ct

10V

AIN

24V

COM

FM+

SYMBOL

Description

Main power input Single-phase: L/N

Braki ng res ist or or connecti ng termi nal: Use d in ca se s where the invert er

frequen tly disco nnects due to la rge load ine rtia or shor t dece lerat ion time

(refer to spe cifica tion s of braki ng resi stor)

For

220V:1HP

DC rea ctor connec ting termin als (bridgi ng conne cti on P1 – P must be

removed for conne cting an DC rea ctor)

Inverter outputs

Description of Terminals of Troubleshooting Inverter

Descriptions of main circuit terminals

Descriptions of SW function

Freque ncy knob (VR = Pote ntiomete r ), when ope rating with option al LED keypad

power sourc e termi nal (pin 3) LEVEL SENSOR,ALARM BUZZER

Analo g frequenc y signa l input termina l or multifunc tion input termi nals S7 (H

leve l:>8V, L level: <2V, PNP only) LEVEL SENSOR

Common conta ct for S1~S5 (S6, S7)in PNP (Source) inp ut. Short-circuit pin 2 and pin

3 (refer to SYNPLUS wiring diagra m) of SW1 when use d PNP input Rotary switc h,optica l sens or

Descriptions of SYNPLUS co ntrol circuit terminals

Description

Multi functi onal termina l – Normal ope n ALARM BUZZER

Multifun ctio nal output

termi nals

HOPPER DIGITAL THERMOSTAT

CYLINDER VALVE

Common conta ct and ana log input /output signa l for S1~S5in NPN (Sink) input .

Short-ci rcuit pin 2 an d pin 3 (refer to SYNPLUS wiri ng dia gram) of SW1 when us ed

NPN input opti cal sensor,ss r,ala rm buzzer

The posi tive ana log output for multi functi on (refer to 8-00 des cription ), the si gnal for

output termi nal is 0-10VDC (belo w 2mA). SSR

Function Descripti on

Multi functi on input termi nals(re fer to 5-00 ~ 5-04 des cripti on)

(S5 = Encoder input te rminal for int egra ted PLC functi onalit y, the Encode r voltage

ran ge: 19.2 V~24.7V)

Was h-rotary swi tch 1

Stan d by-rotar y switc h 2

Soft-rotar y swit ch 3

Hard-ro tar y swit ch 4

opti cal se nsor

Multifun ctio n input termi nals ( Digit al termi nal H level :>8V, L leve l:<2V, PNP only)

o r anal og input termi nal A I 2 ( 0 ~ 1 0 V d c / 4 ~ 2 0 m A ) ( refer to 5-05 des cription )

Display

CPF

EPR

-OV-

-LV-

Display

OC-S

OC-D

OC-A

OC-C

OV-C

Err4

OVSP

Error Cause Remendy

PROGRAM PROBLEM Externa l noise inte rfere nce

Conne ct a para llel RC burs t

abs orber across the magne tizing

coil of the magnetic conta ctor

tha t cause s interferenc e

Volta ge too low

during stop

1. Powe r voltage too low

2. Res tra ining resis tor or fuse burnt out.

3. Det ect ion circui t

mal functi ons

1. Check if the power volta ge

was correct or not

2. Repl ace the restra ini ng res is tor or the fuse

3. Send the inve rte r bac k for

The inve rte r is

overhea ted

during stop

1. Det ect ion circui t mal functi ons

2. Ambie nt tem perature too high or bad ventila tion

1. Send the inve rte r bac k for repa iring

2. Improve ventil at ion condi tions

EEPROM probl em

Faul ty EEPROM Repl ace EEPROM

Volta ge too high

during stop

Detection ci rcui t malfunction

Send the inve rte r back for

repa iring

Over curre nt at

start

1. the motor win d and

enclos ure short ci rcuit

2. the motor contacts and eart h short circ uit

3. the IGBT module ruine d

1.inspect the motor

2.inspect the wire

3.repla ce the tra nsist or modul e

Over-current a t

decelera tion

The pres et decelerat ion time is

too short.

Set a longer de celerat ion ti me

Errors which can be recovered manually and automatically

Error Cause Remendy

Volta ge too high

during opera tion/

decelera tion

1. Dec elera tion time settin g too

short or large loa d inerti a

2. Powe r volta ge varies widely

1. Set a longer decelerat ion time

2. Add a bra ke res istor or brake modul e

3. Add a rea ctor at the power input side

4. Increa se inverter capa city

Ill ega l interrupt

of CPU

Outsi de noise inter feren ce

Send ba ck to rep ai r if it happ ens

many time s

Over-current a t

accel era tion

1. Accel erati on time too short

2. The capacit y of the

motor higher than the

capac ity of the invert er

3. Short circuit betwee n the mot or coil and the

she ll

4. Short circuit betwee n

motor wiring and earth

5. IGBT module damage d

1. Set a longer accele ration time

2. Repl ac e a inverte r with the sa me capa city as that of the

motor

3. Check the motor

4. Check the wiring

5. Repl ace the IGBT module

Over-current a t

fixed spee d

1. Trans ient loa d change

2. Trans ient powe r change

1.Inc rease the capa city of the

inverter

2.Re run param ete r aut o tuning (0-06 = 1)

3. Reduce stator res ista nce (14-0) if the ab ove remedies are

hel ple ss

Over spe ed during

operating

1. Motor loa d too big or Inve rter capac ity too sma ll

2. Motor paramete r error (vector mode)

3. The gain is too big during vector mode opera ting

4. The Curre nt detec t circuit fault

1. Increa se accelera tion /

decele ration time (3-02/3-03)

2. Input corre ct motor Paramete r

3.Cha nge stat or Res ista nce gain and Rotat or res ista nce gain

(14-0/14 -1), sugges t tha t decrea se 50~100 , until 0

4. Send back to SMACH.

Errors which can not be recovered manually

*Error display and remedy

*Error which cannot recovered manually

Display

OL1

OL2

OL3

LV-C

OH-C

Volta ge to o l ow

du ri n g ope rati on

1. Powe r volta ge to o l ow

2. Power vol tage vari e s wi de l y

1. Imp rove power qua l ity or

increa s e the va l ue of 2-01

2. Se t a longe r a ccel e ra tion ti me

3. Increas e i n verter ca p a citor

4. Add a re actor a t the powe r input

He a tsi nk

tempe ra tu re

too Hi gh during

op e ra ti on

1. He a vy load

2. Amb i ent temp e ra ture too hi gh or ba d ven ti la ti on

1. Che ck i f th e re are a ny proble ms wi th the lo a d

2. Increas e i n verter ca p a city

3. Imp rove ven ti la tion condi ti ons

Inve rte r overloa d He a vy Loa d Incre a se the in verter ca p a city

Over torque

1. He a vy Loa d

2. Ins uffi ci ent s e ttings of 9-14,

9-15

1. Increa s e the i nverte r ca paci ty

2. s e t 9-14, 9-15 prope rl y

Over-cu rrent during

s top

1. De tection ci rcui t ma l functi ons

2. Ba d con n e cti on for CT si gnal ca bl e

1.Check the n oi s e be tween Powe r l i n e a nd motor l ine

2.Se nd the i nverte r b a ck for rep a iri ng

Motor overl oad

1. He a vy load

2. I n a p p ropria te s e tti ngs of 0-02, 9-08~11

1. Increa s e the motor capa ci ty

2. s e t 0-02, 9-08~11 p roperl y

Errors which can be recovered manually

Error Cause Remendy

Display

STP0

STP1

STP2

E.S.

b.b.

ATER

PDER

Auto -tun i ng faul ts

1. Moto r da ta e rror res u l ti ng i n fo r a uto-tun i ng fai lure

2. Sto p th e inverter eme rgentl y during Au to -tu n i ng

PID fe e d ba ck l oss PID fe e d ba ck l oss detect

Keypa d

eme rgency stop

1. If the i n verter i s set a s e xtern a l control mod e (1-00=0001) a nd Stop ke y i s e na ble d (1-03=0000), th e i nverter wi ll s top a ccordi ng to the

se tti ng of 1-05 whe n Stop ke y i s pres s ed. STP2 fl as he s afte r s top.

Turn th e op e ra tion s wi tch to OFF a nd the n ON a gain to re s tart th e

inverte r.

2. If the in verter i s in commu ni cati on mod e a nd Stop ke y is ena bl e d (103=0000), the in verter wil l stop in the wa y s et by 1-05 when Stop

ke y i s p re s se d d u ri n g ope rati on a nd the n fl as h e s STP2. The PC ha s

to s e n d a Stop comma nd the n a R un comma nd to the inverte r for i t to

be res ta rted.

3. Sto p ke y ca n not perform eme rgency stop wh e n 1-03=0001

Externa l

eme rgency stop

The in verter wi ll ramp s to p a nd the n fl a sh E.S., when i np ut e xterna l

eme rgency stop s i gna l via the mul tifun cti ona l i nput te rmi na l (refe r to

de s cripti ons of 5-00~5-06).

Externa l b a se

bl ock

The i nverter s top s i mme di ate l y and then fl as hes b.b., when e xte rna l ba se block i s i n put through the multi fun cti ona l i npu t termi n a l (refe r

to de scri p ti o n s of 5-00~5-06).

Special conditions

Error DESCRIPTION

Ze ro s pee d s top Ha p pe ne d when pres e t frequency <0.1Hz

Fa i l to s ta rt directl y

1. If th e i nverter i s set a s e xtern a l termina l control mo de (1-00=1) a n d di rect s ta rt i s di s abl e d (2-04=0001), the in verter ca n not be s tarte d

and wi ll fla s h STP1 when opera ti on switch turne d to ON a fter

applyi ng po wer (re fer to de s criptions of 2-04).

2. Di rect s tart i s pos s ibl e wh e n 2-04=0001.

*Special Condition

Display

LOC

Err1

Err2

Err5

Err6

Err7

Err8

EPr1

EPr2

Parame ter a n d

freque ncy

reve rs e a l ready

lock e d

1.Attempt to mod i fy frequency /pa ra meter whi le 3-17>0000

2.Attempt to re vers e whi l e 1-02=0001

1.Se t 3-17=0000

2. Se t 1-02=0000

Key

op e ra ti on e rror

1.Pres s _ or _whi l e 1-06>0 or runni ng at p res e t s p e e d .

2.Attempt to mod i fy the pa ra mete r ca n no t b e modifi ed during operati o n

(refe r to the pa rame ter l i st).

1.The _ or_ i s avai la ble for modifyi n g the

pa rame ter onl y when

1-06=0

2.Modi fy th e p a rame ter

whi l e STOP

Operation errors

Error Cause Remendy

Commun i cati o n

fa i le d

1.Wi ri n g error

2 .Comm uni ca ti on p a rame ter s e tti ng

error.

3.Sum-ch e ck e rror

4.Incorrect commu n i ca tion proto col

1.Check ha rdwa re a nd wi ri ng

2.Check Fu ncti on 13-1~13-4

Parame ter

confl ict

1.Attempt to mod i fy the fu ncti on 15-0 or 15-7

2.Vol tage a nd cu rrent detecti on ci rcui t is abnormal

If Res e t i nverter is no t

avai l abl e , pl ea s e s end the

inverte r b a ck for repa ir

Parame te r s e tti ng

error

1. 3-01i n th e range of 3-13 ± 3-16 or 3-14 ± 3-16or 3-15 ± 3-16

2. 3-00≤3-01

3.The s e tti ng e rror a s performi n g Auto tun i n g(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 du ri n g Auto tun i ng

Modi fi cati on o f

pa rame ter i s

no t a vai l a ble i n

communica ti on

1.Is s u e a control command duri ng communica ti on d i sa bled

2.Modi fy th e functi on 13-1~13-4 du ri ng commu ni ca tion

1.Iss u e ena bl e co mma n d be fore commu n i ca tion

2.Se t th e very pa ra mete r of thefu ncti onb e fore

communica ti on

Parame ter no t

ma tch

Copy the pa rame ter to i n verter to

veri fy the pa ra meter i s not ma tch.

1.Re write a gai n

2.Re pl a ce copy u ni t

Fa cto ry s e tti ng

error

When PLC is Ru nning, Pe rform

fa cto ry s e tti ng

Plea s e perform fa ctory

s e tti n g before PLC s tops .

Parame te r s e tti ng

error copy uni t

fa i le d

1.Se t 3-18=1.2 wi thout conne cting copy uni t.

2. Copy un i t fai l e d.

1.Modi fy 3-18

2.Re pl a ce copy u ni t

*Operation Errors

Status

General troubleshooting

Checking point

Remedy

• Is a na l o g fre que ncy in put s i gna l wiri ng correct?

• Is vol ta ge o f fre quency i nput correct?

Is opera ti o n mo d e s etti ng corre ct?

• Opera te o perati o ns th rough the di gita l

pa nel.

Motor run s

inve rs el y

Are wi ring for o utput termi n a l s T1, T2, a nd T3

corre ct?

• Wi ring must ma tch U, V, a nd W te rmin a l s o f the motor.

Are wi ring for forwa rd a nd re vers e s igna ls

correct?

• Che ck wiri ng a re correct i f ne ces s ary.

Motor ca n n ot

run

Is powe r a ppl ie d to L1(L), L2, a nd L3(N)

termi n a l s (i s the cha rgi ng i ndi cator l i t)?

• Is th e po we r ap pl i e d ?

• Turn the power OFF a nd then ON aga in.

• Make su re th e po we r vol tage is correct.

• Make su re s crews are se cured fi rml y.

Are the re vol tage acros s the outpu t te rmi na l

T1, T2, a nd T3?

• Turn the power OFF a nd then ON a gai n.

Is o verloa d ca u s ing th e motor b l ocke d?

• Re duce th e loa d to l e t the motor

running.

Are there a ny a bnormal i tie s in the i nverte r?

• Se e e rror de scri pti ons to ch e ck wi ring

a nd corre ct i f ne ce s sa ry.

Is forwa rd or revers e runn i ng comma nd i s sued?

Motor s p e e d

vari es

un us u a l ly

Is th e l oad too he a vy? • Re duce th e loa d.

Does the lo a d va ry l a rge l y?

• Mi nimi ze the vari a ti on o f the l oa d.

• Increa se cap a ci tie s of th e i nverte r a nd the motor.

Is th e i npu t p owe r l ack of p ha s e?

• Add a n AC re a ctor a t the powe r i npu t si d e i f us ing s i n gl e-p ha s e powe r.

• Che ck wi ring if u s ing thre e -ph a s e po we r.

Motor

running

speed too

hi gh or too

low

Are s peci fi cati ons of th e motor (pol es ,

vol ta ge…) co rrect?

• Con fi rm the m otor’s sp e ci fica tions .

Is th e gea r ra tio corre ct? • Confi rm th e gea r ra tio.

Is the s etti n g of th e h i ghe st o utpu t frequ e n cy

correct?

• Con fi rm th e h i ghes t o u tput fre que ncy.

The moto r speed ca n

no t be

regul a te d .

Are wi ring for a na l o g fre quency i nputs co rrect? • Che ck wi ri n g a re correct i f neces s ary.

Is the s etti n g of operati on mo de correct?

• Che ck the operati on mo de of the op e ra tor.

Is th e l oad too he a vy? • Re duce th e loa d.

Ha s ana log frequ e n cy s i gna l be en i nput?

*General Troubleshooting of Inverter

*Quick Troubleshooting of Inverter

Inverter

Fault

7. INVERTER CONTROL BY A LAPTOP

Inverter settings can be changed by the program named

SYNPLUS

and to connect to inverter over a laptop

RS232 cable is needed. Then follow the instructions to change settings.

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 m

achine parts which are subjected to the mix or ice

proper brushes and sanitized then mounted again. In mounting process especially for O

used. Below there is information about the sanitizer.

cream must be cleaned by using

ring suitable oil must be

Moreover, the ice-

cream mix in the hopper must be kept around 4C. This is the best temperature for the

count the least. And if the

temperature of the

max. 140 minutes to reach

the temperature around 4C.

panel and check the thermostat as seen in the photo below.

around -2C

(this is the average temperature of antifreeze whic

is around +4C in the tank(hopper).

mix poured into the hopper

is around room temperature It must take

To control the hopper

temperature,

The thermostat which is closed to inverter must show

h is in a tank below the hopper)

bacteria

remove the left side

so this means the mix

9.EXPLODED VIEWS

Smach EFE 1500, EFE 2500P Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual