Savage Bros FireMixer-14 User manual

`
SAVAGE BROS. CO.
Installation, Operation, Maintenance
and Parts Manual
January 2022
Savage Bros. Co.
1825 Greenleaf Avenue
Elk Grove Village, Illinois 60007 –USA
Phone: [phone]
World Fax: [phone]
USA Fax: [phone] (800-2-SAVAGE)
Internet: www.savagebros.com
E-mail: [email protected]

[FireMixer-14 Installation, Operation, Maintenance and Parts Manual]
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CONTENTS
FireMixer-14 Table-Top Cooker (FM-14)
CONTENTS..............................................................................................................................................................2
GENERAL CONCEPT OF OPERATION ......................................................................................................................4
IMPORTANT SAFETY MEASURES............................................................................................................................5
INITIAL INSTALLATION ...........................................................................................................................................7
TURNING ON THE MACHINE..................................................................................................................................9
COOKING CONTROL SCREEN................................................................................................................................10
Cooking Control Screen ...................................................................................................................................11
MAINTENANCE SCREEN ...................................................................................................................................27
ADVANCED SETTINGS SCREEN.........................................................................................................................31
COOKING A BATCH...............................................................................................................................................46
LOAD THE COOKER...........................................................................................................................................46
PROGRAM THE TEMPERATURE........................................................................................................................46
HEAT AND AGITATE..........................................................................................................................................47
WATER-FLUSH AT COOKING CYCLE END..........................................................................................................47
UNLOADING PRODUCT FROM THE COOKER...................................................................................................48
CLEANING THE COOKER.......................................................................................................................................49
Cooker Cleaning...............................................................................................................................................49
Agitator Cleaning .............................................................................................................................................49
Exterior.............................................................................................................................................................49
Lubrication.......................................................................................................................................................50
Inspection ........................................................................................................................................................50
Main Control Box .............................................................................................................................................50
TROUBLESHOOTING.............................................................................................................................................51
PRODUCT TEMPERATURE DISPLAY INACCURATE............................................................................................52
OVERCOOKING / PRODUCT SCORCHING.........................................................................................................52
OVER COOKING / TEMPERATURE CONTINUES TO RISE AFTER SHUTOFF........................................................53
CONTENTS

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TILT SWITCH INOPERATIVE ..............................................................................................................................53
TANK WATER FLUSH INOPERATIVE..................................................................................................................53
AUDIBLE ALARM NOT HEARD ..........................................................................................................................54
HEATER INOPERATIVE......................................................................................................................................54
HEATER INOPERATIVE (continued)..................................................................................................................55
AGITATOR DOES NOT ROTATE.........................................................................................................................56
AGITATOR DOES NOT ROTATE (continued).....................................................................................................57
WARRANTY POLICY..............................................................................................................................................58
Obtaining Replacement Parts During the Warranty........................................................................................58
MECHANICAL DRAWINGS, PARTS LISTS & ETC. ...................................................................................................59
Cooker Main Assembly ....................................................................................................................................60
Cooker Shaft Removal......................................................................................................................................61
Agitator Bottom Drive......................................................................................................................................62
Cooker Bottom Scraper ...................................................................................................................................63
Nut Stirrer Agitator..........................................................................................................................................64
Motor Mount Assembly Field Assembly Procedure........................................................................................65
Agitator Options ..............................................................................................................................................66
ELECTRICAL SCHEMATICS & ELECTRICAL PARTS LIST ..........................................................................................67
ELECTRICAL SCHEMATICS & ELECTRICAL PARTS LIST / INTERNATIONAL ............................................................72
ELECTRICAL SCHEMATICS & ELECTRICAL PARTS LIST W/ MINI PUMP.................................................................78

[FireMixer-14 Installation, Operation, Maintenance andParts Manual]
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GENERAL CONCEPT OF OPERATION
GENERAL CONCEPT OF OPERATION
Control Panel
1. The Savage Bros. Co. Table-Top Cooker is an
electric cooker/mixer. Safe operation of the
equipment is very important. Personnel that
will work in the area of the machine must become
familiar with the potential hazards.
2. The PLC (Programmable Logic Controller) is used by
the machine for accurate cooking control. With a
single point of operation, both product and cooker
temperatures can be monitored and controlled
more accurately.
3. The optional “Data Logging” feature records a
variety of essential data during the cook
process including time, temperature, setpoint
and batch count.
4. An electric scraper agitator stirs the product. The
agitator is a rotating mechanical device. The
agitator will not automatically stop if a body
part, clothing or a rigid item gets caught in it. Keep
hands and body clear of the rotating agitator.
5. The standard 208-240VAC 50/60Hz unit has a 3,000
watt electric heating element and a 1/8HP agitator
motor with a gearbox designed for 150 inch-
pounds of torque at 28 RPM.
6. The cooker is a tilting cooker, encased in a stainless
steel cylinder. Within the cylinder is the electric
heating element formed to fit the cooker bottom.
A temperature sensor monitors the cooker skin
temperature.
7. The cooker and the product being cooked may
become very hot during operation. Although the
cooker surface is insulated, take precaution not to
allow bare skin to contact the cooker cylinder
surface. The FM-14 has a water-flush cooling
feature to control the cooking and speed up the
cooling process.
8. A second temperature sensor is mounted along the
agitator shaft and monitors the product
temperature while the product is cooking.
Product
Temperature
Sensor
Agitator
Tilting Cooker
Heating
Element
/ Temp.
Sensor
(below)
Water
Flush
Cooling
Feature

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IMPORTANT SAFETY MEASURES
General
Moving any type of machinery presents a risk of injury. This cooker weighs approximately 150 lbs. (68 kg).
The FM-14 tilts and agitates, which means the operator(s) must be alert at all times. Anyone who will operate
the FM-14 must have training in its function and care.
1. It is strongly recommended that a qualified electrician perform all electrical work.
2. The machine requires a 208/240 volt, 50/60 Hz, 1 phase power source and a 20 amp fuse or circuit
breaker protecting the circuit.
3. Before working on the machine —installation and maintenance —ensure the machine is properly
locked out-tagged out.
Safety Rules
•Do not operate the FM-14 or other machinery if you:
oAre tired; or
oHave been drinking alcohol; or
oAre taking any medication that makes you drowsy or sleepy.
•When operating, inspecting or maintaining the FM-14, always follow all work shop rules, safety
regulations and precautions.
•Always pay attention to what you are doing and to other people in the area and surrounding conditions.
•Do not use the FM-14 for anything other than its intended purpose.
•Do not use broken tools or tools designed for another purpose for inspection or maintenance.
•SAFETY IS UP TO YOU.
IMPORTANT SAFETY MEASURES

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•Modifications of any type to the FM-14 without specific written authorization from Savage Bros. Co. can
create unknown hazards and voids the warranty.
•Before making any modification, consult the manufacturer. Savage Bros. Co. will not be responsible for
any injury or damage caused by any unauthorized modification.
•Obstruction or limitation of movement and/or operator view can result if unauthorized equipment or
parts are added to the FM-14.
Unauthorized Modification

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INITIAL INSTALLATION
1. The cooker weighs approximately 150 lbs. (68 kg). Therefore, when removing the cooker from the
shipping crate, lift up on the base or from below the cooker. Two or more people are required to lift
the cooker.
2. Place the machine on a solid, level surface. To ensure the cooker is level, place a level atop the
cooker. If the cooker is not level, the machine’s four feet (arrows) are individually adjustable and are
used to level the machine, Fig. 1.
3. To adjust the height of an individual leg, Fig. 2:
a. Using an open-end wrench, loosen the locknut (A).
b. Place a bubble level atop the cooker.
c. Insert an open-end wrench onto the wrench flats (B) of the leg.
Turn the wrench to increase or decrease the height of the
individual leg while observing the level.
d. Once the machine is level, remove the bubble level.
e. Using an open-end wrench, tighten the locknut (A).
f. It may be necessary to adjust two or more legs for the machine
to be perfectly level. Repeat steps a through e for other legs as
needed.
INITIAL INSTALLATION
Figure 1
Figure 2

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4. Ensure the red Emergency Stop (E-Stop), (arrow), Fig. 3,
located on the front of the machine, is pushed into the STOP
position.
5. The FM-14 has a water-flush cooling feature. Connect the
blue hose, which has a standard hose fitting on the open end,
to a cold-water source (Fig. 3.1) —a sink faucet is commonly
used. Having water flow through the system removes heat
from the cooker bottom, slowing the cooking process near
the end of the batch.
6. The metal braided hose, which has a standard hose fitting on
the open end, allows the water to drain from the machine.
Connect another hose to the metal braided output hose, then
route the hose assembly to a drain.
NOTE: The drain hose must remain open to the atmosphere to
avoid pressurizing the cooker. Do not restrict the drain hose in any
way, for example, by putting on an excessively long hose, a small
diameter hose, or routing the hose vertically, creating back pressure.
Figure 3.1
Blue Hose
(Cold water in)
Metal Braided
Output Hose
(Draining)
Figure 3

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TURNING ON THE MACHINE
1. Insert the machine’s electrical plug into a Nema 6-20r electrical outlet.
2. The E-Stop Reset screen appears, Fig. 4, if the E-Stop button is depressed, Fig. 5. To advance to the
next screen, wait for ten seconds, which gives time for the VFD (Variable Frequency Drive) to
discharge, then pull out the E-Stop button (arrow), Fig. 5.
3. If this screen appears, after reading the WARNING, press
the Verify and Continue button, Fig. 6.
TURNING ON THE MACHINE
Figure 4
Figure 5
Figure 6

[FireMixer-14 Installation, Operation, Maintenance andParts Manual]
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COOKING CONTROL SCREEN
The following icons may be used on the FM-14 HMI screens:
Agitator
Maximum Cook
Power
Jog
Chef Mode
Low Cook
Run
Flush
High Cook
Speed
Chef Mode
Auto Shutdown
Minimum
Cook
Temperature
Locked
Medium
Settings
Unlocked
Maximum
Advanced
Settings
Exit
VFD Speed HSP in
HZ
Cook Cycle ON
Accept
Command
Cook Cycle OFF
Product
Temperature
Attained
Minimum
Temperature
Cooker Tilted
Help
Maximum
Temperature
Lid Switch
Information
Factory Settings
Alarm
Maintenance
Reset
Cooker
Silence Alarm
HMI Brightness
COOKING CONTROL SCREEN

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Cooking Control Screen
The Cooking Control screen, Fig. 7A, is used as the starting point. From this screen you can select the Main
Popup Menu from which you can open the Maintenance screen and the Advanced Settings screen and the
Help/Information Screen. You can also select the Chef Mode On/Off screen. You can also select High Cook or
Low Cook, start and Stop the Cook Cycle, turn the Agitator On and Off, select Agitator speed, open, and
close the Flush and turn the Cook Audible On/Off. Familiarize yourself with all of the screens, controls,
settings, and indicators, prior to making a batch. Operate the cooker from the Cooking Control Screen,
Fig. 7.
Figure 7
High Cook
On/Off
Menu
Actual
Product
Temperature
Cook Audible
On/Off
Agitator ON/OFF /
Agitator Speed
Button
Agitator LMH or
RPM Speed
Indicator
Cook Cycle
Temperature Graphical
Indicator (red)
Kettle Upright /
Tilt Position
Indicator
Flush
Open/Close
Product Temperature Setpoint /
Cook Audible Setpoint
Cook Cycle
Start/Stop
Cook Status
Indicator
Cook Audible
and above
Graphical
Indicator
(yellow and
orange)
Low Cook
On/Off
Chef Mode On/Off
Current PLC
Date and Time
Message Status
Area

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COOK CONTROL SCREEN FUNCTIONS AND MAIN POPUP MENU FUNCTIONS
The following are explanations of the Cook Control Screen functions (refer to
Fig.7):
•Menu —Pressing the Menu icon brings up the Menu Popup Window
•Actual Product Temperature —Displays the Actual Product Temperature.
•Message Status Area —Messages are displayed at the top portion of the Cook Control Screen.
•Product Temperature Setpoint / Cook Audible Setpoint —Pressing the icon brings up the Popup
Window where the setpoint of the product temperature and the setpoint of the Cook Audible can be
entered.
•Cook Audible —Pressing the icon will Enable / Disable the Cook Audile mode.
The “Cook Audible” is an option that can be used to notify the operator by visual and audible means,
when a preset temperature, selected anywhere along the cooking process is reached, for example to
indicate when to add an ingredient.
•Flush Open /Closed Indicator —Indicates Flush Open / Flush Closed status.
•Cook Status Indicator —Indicates, Ignite, Low Heat, and High Heat statuses of the burner.
•Kettle Upright Position / Kettle Tilt Position Indicator —Indicates Kettle In Upright Position / Kettle
Tilt Position.
•Cook Cycle Graphical Indicator —Graphically Indicates the temperature of the cook cycle.
•Agitator Speed Indicator —Indicates the preset speed of the Agitator LMH (LOW, MEDIUM, HIGH) or
RPM Speed (option selected in Advanced Settings, refer to Pg. 33).
•Agitator ON/OFF / Agitator Speed Button—Turns Agitator ON/OFF as well as Agitator LMH (LOW,
MEDIUM or HIGH or RPM Speed Popup Window (after pressing and holding).
•Chef Mode On/Off —in Chef Mode, the operator can view and adjust the setpoint for the Kettle
Temperature.
•High Cook —In High Cook mode, the product cooks at a higher rate.
•Low Cook —In Low Cook mode, the product cooks at a lower rate.

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The following are explanations of the Main Popup Menu functions (refer to
Fig. 8):
•Current PLC Date and Time —Pressing the icon will display the Current PLC Date and Time.
•Maintenance—Pressing the icon will bring up the Maintenance screen.
•Advanced Settings —Pressing the icon will bring up the Advanced Settings screen.
•Help / Information —Pressing the icon will bring up the Help / Information screen, refer to Pg. 45.
•Exit —Pressing the icon will exit without changes.
Current PLC Date
and Time
Advanced Settings
Help / Information
Exit
Main Popup Menu
Figure 8
Maintenance

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CURRENT PLC DATE AND TIME
To display “Current PLC Date and Time” press the
“Current PLC Date and Time” button on the top right, on
the Cooking Control screen, (Fig.9), which will bring up
the “Current PLC Date and Time” popup window, (Fig
10). The “Current PLC Date and Time” can be changed
(refer to “Advanced Settings Screen”. Press the “Exit”
button to exit without changes.
Figure 9
Figure 10
Current PLC Date and
Time Popup Window
Exit
Current PLC Date and
Time Button

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Product Temperature Setpoint
By touching the Temperatures Setpoint (white
numbers), (Fig. 11), a popup window will appear, Fig. 12.
Touch the Product Temperature Setpoint (top, black
numbers, white background) in the popup window and
a numeric keypad will appear, Fig. 13. Type in the
desired temperature. The desired temperature can be
changed before, after and during the cook cycle.
The maximum product temperature is 350 °F (177 °C).
Press the Exit button to exit without changes.
Figure 11
Figure 13
Figure 12
Popup Window
Product Temperature Setpoint
(top, black numbers, white background)
Exit
Numeric Keypad
Temperature Setpoint (white numbers)

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When the Product Temperature Setpoint is attained, the
product Actual Product Temperature flashes green, an
audible alarm turns on and Product Temperature
Attained (with Accept symbol) is displayed in the Cook
Status Indicator Area, Fig. 14. When this message
appears, the user has one of three options:
•Press the Cook Cycle Stop button, which turns the
heater off; or
•Increase the temperature setpoint and the unit
resumes cooking until the new temperature setpoint
is reached; or
•Do nothing, and the unit cycles the heater on and off
to maintain the setpoint, unless the Auto Shutdown is
turned on. In the case that the Auto Shutdown is
turned on, (see Pg. 18 for info on Auto Shutdown) the
cooking process will turn off after two hours from the
point of pressing the Cook Start, as long as the
maximum heat power is greater than 30 %.
Cook Audible Setpoint
The “Cook Audible” is an option that can be used to
notify the operator by visual and audible means that the
preset temperature, has been reached, for example to
indicate when to add an ingredient.
The Cook Audible Setpoint can be set by touching the
Temperatures Setpoint, Fig. 15 after which a Popup
Window will be displayed, Fig. 16.
On the Popup Window, press on the Cook Audible
Temperature Setpoint (bottom, black numbers with
white background), after which a numeric keypad will be
displayed. On the numeric keypad enter the desired
setpoints. Press the Exit button to exit without changes.
The Cook Audible can be turned
On/Off by pressing the Cook
Audible button. When turned
on, the Cook Audible On/Off
icon background turns yellow,
Fig. 16.
Figure 14
Figure 15
Figure 16
Cook Cycle Start/Stop
“Product Temperature
Attained“ is displayed
.
Actual Product
Temperature flashes
Green at Setpoint.
Cook Audible
On/Off button
Cook Audible
Setpoint
(bottom, black
numbers, white
background)
Popup Window
Temperatures Setpoint (white numbers)
Exit

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Figure 17
When the Cook Audible Setpoint is attained, an
audible alarm turns on, until the alarm is
acknowledged, the Actual Product Temperature
(numeric value) flashes yellow and red, Fig. 17,
alerting the operator the product temperature has
reached the Cook Audible Setpoint. The alarm can be
acknowledged by once more pressing the Cook
Audible On/Off button.
Cook Cycle Start/Stop Button
Pressing the Cook Cycle Start/Stop button starts the
cooking process, Fig. 18. When Cook is in the Stop
position, the background on the Cook Cycle Start/Stop
button is grey. To turn the heater on, press the Cook
Cycle Start/Stop button to Start, at which point, its
background turns green. At this point a red, flashing
Heater Image appears, in the Cook Status Indicator,
and the Cook Cycle Temperature Graphical Indicator
turns red, Fig. 19.
During the Cook Cycle, pressing the Cook Cycle
Start/Stop button to Off will turn the heater off again,
which causes its background color to revert to grey,
also the red flashing Heater Image and the Cook Cycle
Temperature Graphical Indicator to turn off, Fig 19.
Figure 18
Cook Audible Setpoint
and Above indicator
Cook Cycle Start/Stop - Stopped
Figure 19
Red, Flashing Heater Image, in
Cook Status Indicator
Cook Cycle Temperature
Graphical Indicator
Cook Cycle Start/Stop - Started
Cook Audible On/Off
Actual Product Temperature
flashes yellow and red.

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Auto Shutdown
Two hours after pressing the Cook Start, and if the
maximum heat power is greater than 30 % and the Auto
Shutdown is turned On (on the Advanced Settings
screen, Pg. 33), the cooking process will be shut down. A
countdown screen will be displayed 10 minutes prior to
Auto Shutdown, Fig. 20. If the countdown screen is
exited, it will reappear at 5, 2, and 1 minute prior to
Auto Shutdown. The Auto Shutdown Timer can be reset
by pressing the Reset Button. Press “Exit” to exit without
changes.
Flush Open/Closed Button
The flush valve can be opened/or closed by selecting the
Flush Open/Closed button, on the bottom right of the
screen Fig. 21. When it is open, the Cook Cycle
Temperature Button background turns blue.
Opening the flush removes the heat from the cooker to
stop or slow the cooking process.
Agitator Start/Stop Button
Pressing the “Agitator Start /Stop button momentarily
either starts or stops the agitator, Fig. 22. The agitator
automatically stops if the cooker tilts past a certain
point. The agitator cannot start turning again until the
cooker is upright.
Figure 20
Figure 22
Reset
Figure 21
Flush Open/Closed button
Flush open shown.
Agitator Start/Stop
Exit
Cook Cycle Temperature
Indicator turns Blue.

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Agitator Speed
The Agitator runs on two different speed modes. To
change Agitator speed mode, first open the Advanced
Settings screen, Fig. 23, refer to Pg. 31 and follow it to
the Advanced Settings screen, Pg33. On the Advanced
Settings screen select between Agitator LMH ( Low,
Medium High) or RPM speed mode. Once the desired
Agitator speed mode is selected, exit to the Cook
Control screen.
On the Cook Control screen, press and hold the Agitator
ON/OFF / Agitator Speed button, Fig. 24, which will bring
up an Agitator popup window, depending on the speed
mode. When in LMH mode, on the popup window, select
LMH (Low, Medium High), Fig. 25. Press “Exit” to exit
without changes.
Figure 23
Agitator LMH
/ RPM
Figure 24
Figure 25
Agitator High Speed
Agitator Medium
Speed
Agitator Low Speed
Agitator On/Off
Press and hold
Agitator ON/OFF /
Agitator Speed
button.
Exit

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When in RPM mode, on the popup window, press on
the Agitator RPM Setpoint button, Fig. 26, which will
bring up a numeric keypad. On the keypad, type in the
desired Agitator RPM speed, then press Enter. Press
“Exit” to exit without changes.
Pressing the “Agitator Information” button, Fig. 26 will
bring up the “Agitator Information” Popup window”
which will display Agitator Information, Fig. 27. Press
“Exit” to exit without changes.
Agitator Speed Control –Torque Limiting
The agitator will automatically respond to load conditions and will decrease or increase agitator speed,
depending on the agitator load (current on the Agitator Drive).
Agitator speed control, if enabled, will automatically slow the speed of the agitator when the agitator
motor is experiencing high current. This is done to keep the agitator running and to prevent damage to
the agitator.
How it works
The motor current (LCR) and the rated motor current (NCR) are read from the VFD. When the agitator is
running, these values are compared.
If the motor current is at or above 100% of the rated current, the speed is dropped by 1 RPM every 8
seconds activating the speed reduction.
If the motor current is at or above 110% of the rated current, the speed is immediately reduced to 6
RPM also activating the speed reduction.
Figure 27
Press on the Agitator
RPM Setpoint Button.
Agitator On/Off
Agitator
Information Button
Figure 26
Agitator RPM Display
Exit
Agitator Information
Popup Window
Exit