Smach EFE 4000 User manual

SOFT-SERVE AND FROZEN YOGHURT FREEZER
SERVICE MANUAL
MODEL: EFE 4000
Manual Number: V 001 - 17.05.2012

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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

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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 3 0° 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 - C when beater turns. Machine checks the current in the beater motor by an inverter when the
current is around 2. Amp 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

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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

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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
2 Compressor starts then stops
after few seconds without
Air Not circulating Clereances should be 50 cm.
3 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
4 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
5 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
6 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
8 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
9 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
10 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)
Mix contain hard pieces/nuts Take out the mix, filter&pour in.

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6.2.Inverter Troubleshooting
*Description of Terminals Troubleshooting in erter
SYMBOL
R\L1(L)
S\L2
T / L3 ( N )
P1
BR
P1/ P
U / T1
V / T2
W / T3
SYMBOL
R2A
R2B
R1C
Common contact
R1B
Normal close contact
R1A Normal open contact
10V
AIN
24V
COM
FM+
SYMBOL
S1
S2
S3
S4
S5
S
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)
For
220V:1HP
DC rea ctor connecting terminals (bridging connection P1 – P must be
removed for connecting an DC rea ctor)
Inverter outputs
Description of Terminals of Tro bleshooting Inverter
Descriptions of main circ it terminals
Descriptions of SW f nction
Frequency knob (VR = Potentiometer ), when operating with optional LED keypad
power source terminal (pin 3) LEVEL SENSOR,ALARM BUZZER
Analog frequency signal input terminal or multifunction input terminals S7 (H
level:>8V, L level:<2V, PNP only) LEVEL SENSOR
Common contact for S1~S5 (S , 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
Descriptions of SYNPLUS control circ it terminals
Description
Multifunctional terminal – Normal open ALARM BUZZER
L
Multifunctional output
terminals
HOPPER DIGITAL THERMOSTAT
CYLINDER VALVE
Common contact and analog input /output signal for S1~S5in NPN (Sink) input.
Short-circuit pin 2 and pin 3 (refer to SYNPLUS wiring diagra m) 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
Function Description
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)
Wash-rotary switch 1
Stand by-rotary switch 2
Soft-rotary switch 3
Hard-rotary switch 4
optical sensor
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)

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Display
CPF
EPR
-OV-
-LV-
OH
Display
OC-S
OC-D
OC-A
OC-C
OV-C
Err4
OVSP
Error Ca se Remendy
PROGRAM PROBLEM External noise interference
Connect a parallel RC burst
absorber across the magnetizing
coil of the magnetic contactor
that causes interference
Voltage too low
during stop
1. Power voltage too low
2. Restraining resistor or fuse
burnt out.
3. Detection circuit
malfunctions
1. Check if the power volta ge
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
EEPROM
problem Faulty EEPROM Replace EEPROM
Voltage too high
during stop Detection circuit malfunction Send the inverter back for repairing
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
1.inspect the motor
2.inspect the wire
3.replace the transistor module
Over-current at
deceleration
The preset deceleration time is
too short. Set a longer deceleration time
Errors which can be recovered man ally and a tomatically
Error Ca se Remendy
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
Illegal interrupt
of CPU Outside noise interference Send back to repair if it happens many times
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
Over-current at
fixed speed
1. Transient load change
2. Transient power change
1.Increase the capacity of the
inverter
2.Rerun parameter auto tuning
(0-0 = 1)
3. Reduce stator resistance (14-0)
if the above remedies are
helpless
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.Cha nge stator Resistance gain
and Rotator resistance gain
(14-0/14-1), suggest that
decrease 50~100, until 0
4. Send back to SMACH.
Errors which can not be recovered man ally
*Error display and remedy
*Error which cannot reco ered manually

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Display
OC
OL1
OL2
OL3
LV-C
OH-C
Vol tage too low
during operation
1. Powe r vol ta ge too l ow
2. Power vol tage varies widely
1. Improve power quality or
increa s e the value of 2-01
2. Set a longer acceleration time
3. Increa s e i nverter capacitor
4. Add a reactor a t the power
input
s i de
Heatsink
temperature
too Hi gh duri ng
operation
1. Hea vy load
2. Ambi ent temperature too
high or ba d venti lation
1. Check if there a re any
probl ems with the loa d
2. Increa s e inverter capa city
3. Improve ve ntila ti on
condi tions
Inverte r overl oa d Heavy Loa d Increa s e the inverter capa city
Over torque
1. Hea vy Loa d
2. Ins uffi cient s e ttings of 9-14,
9-15
1. Increa s e the i nverter ca pacity
2. s et 9-14, 9-15 properly
Over-current duri ng
s top
1. Detection circui t
ma l functi ons
2. Ba d connection for CT
signal ca ble
1.Check the noise between Power
l ine a nd motor line
2.Send the i nverter ba ck for
repa i ri ng
Motor overloa d
1. Hea vy load
2. I nappropria te s ettings of
0-02, 9-08~11
1. Increa s e the motor ca pacity
2. s et 0-02, 9-08~11 prope rly
Errors which can be recovered man ally
Error Ca se Remendy

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Display
STP0
STP1
STP2
E.S.
b.b.
ATER
PDER
Auto-tuni ng faults 1. Motor da ta error resulti ng i n for a uto-tuni ng fa i lure
2. Stop the i nverter emergently during Auto-tuning
PID feedback loss PID feedba ck los s detect
Keypad
emergency s top
1. If the i nverter is s et as external control mode (1-00=0001) a nd Stop
key i s ena bl ed (1-03=0000), the i nverter wi ll stop a ccordi ng to the
setting of 1-05 when Stop key is pres s ed. STP2 flashes a fter stop.
Turn the operati on s wi tch to OFF and then ON a ga in to restart the
inverter.
2. If the inverter i s in communi cation mode a nd Stop key is ena bl ed (1-
03=0000), the inverter wi l l s top in the wa y set by 1-05 when Stop
key is pres s ed during operation and then fl ashes 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 ta rted.
3. Stop key cannot perform emergency stop when 1-03=0001
Externa l
emergency s top
The i nverter will ramp s top a nd then fl a s h E.S., whe n i nput external
emergency s top s igna l via the multifunctiona l i nput termi na l (refer to
des cripti ons of 5-00~5-0 ).
External base
block
The i nverter s tops i mmedi atel y and then flashes b.b., when externa l
base bl ock i s i nput through the mul tifuncti ona l i nput termi na l (refer
to descri ptions of 5-00~5-0 ).
Special conditions
Error DESCRIPTION
Zero s peed stop Ha ppened when pres et frequency <0.1Hz
Fail to s tart directly
1. If the i nverter is s et a s externa l termina l control mode (1-00=1) and
di rect start is disabled (2-04=0001), the i nverter cannot be s ta rted
and will flash STP1 when ope ration s wi tch turned to ON a fter
appl ying power (refer to descri ptions of 2-04).
2. Di rect start i s pos s i bl e when 2-04=0001.
*Special Condition

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Display
LOC
Err1
Err2
Err5
Err
Err7
Err8
EPr1
EPr2
Para meter a nd
frequency
revers e a lre ady
locked
1.Attempt to modify frequency
/pa rameter while 3-17>0000
2.Attempt to reverse while 1-02=0001
1.Set 3-17=0000
2. Set 1-02=0000
Key
opera ti on error
1.Press _ or _whi le 1-0 >0 or
runni ng a t pres et s pe ed.
2.Attempt to modify the pa rameter ca n
not be modi fied during opera tion
(refer to the pa rameter l i st).
1.The _ or_ is a vail able
for modifying the
pa rameter onl y when
1-0 =0
2.Modi fy the pa rame ter
whi le STOP
Operation errors
Error Ca se Remendy
Communi cation
fail ed
1.Wi ring error
2 .Communi cation pa rameter setti ng
error.
3.Sum-check error
4.Incorrect communicati on protocol
1.Check ha rdwa reand wi ring
2.Check Functi on 13-1~13-4
Parameter
confli ct
1.Attempt to modify the function 15-0
or 15-7
2.Voltage a nd current detecti on circui t
is a bnormal
If Reset inverter i s not
ava ilable, pl eas e s end the
inverter ba ck for repair
Parameter s etting
error
1. 3-01in the range of 3-13 ± 3-1 or
3-14 ± 3-1 or 3-15 ± 3-1
2. 3-00≤3-01
3.The s etting error a s performing Auto
tuning(e.g. 1-00 ≠ 0_1-0 ≠ 0 )
1.Modify 3-13~3-15or 3-1
2. 3-00>3-01Set 1-00=0, 1-
0 =0 during Auto tuni ng
Modi fi cation of
pa rameter is
not ava ila ble in
communi cation
1.Is sue a control comma nd during
communi cation di s abled
2.Modi fy the function 13-1~13-4
during communi cation
1.Is sue ena bl e comma nd
before communi ca tion
2.Set the very pa rameter
of thefunctionbefore
communi cation
Para meter not
match
Copy the pa rameter to inverter to
verify the pa rameter i s not ma tch.
1.Rewri te aga in
2.Repl ace copy uni t
Factory setting
error
When PLC is Running, Perform
factory s etting
Pleas e perform fa ctory
s etti ng before PLC s tops .
Parameter s etting
error copy uni t
fail ed
1.Set 3-18=1.2 wi thout connecting
copy unit.
2. Copy uni t fail ed.
1.Modi fy 3-18
2.Repl ace copy uni t
*Operation Errors

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Stat s
General tro bleshooting
Checking point
Remedy
• Is analog frequency i nput signal wiring
correct?
• Is volta ge of frequency i nput correct?
Is operation mode setting correct?
• Operate opera ti ons through the di gi tal
pa ne l.
Motor runs
inversel y
Are wiri ng for output termi nals T1, T2, a nd T3
correct?
• Wi ring mus t ma tch U, V, a nd W terminals of the
motor.
Are wiri ng for forwa rd and revers e s i gna ls
correct? • Check wiring a re correct if neces s ary.
Motor ca n not
run
Is power a ppl ied to L1(L), L2, and L3(N)
terminals (i s the cha rging i ndi cator l it)?
• Is the power appl ied?
• Turn the power OFF a nd then ON
aga in.
• Make s ure the power vol tage is correct.
• Make s ure screws a re secured fi rml y.
Are there vol tage a cros s the output termi na l
T1, T2, and T3?
• Turn the power OFF a nd then ON a ga in.
Is overload caus ing the motor bl ocke d?
• Reduce the load to let the motor
runni ng.
Are there any a bnormali ties in the i nverter?
• See error des criptions to check wiri ng
a nd correct if neces sary.
Is forwa rd or revers e runni ng command iss ued?
Motor s peed
varies
unus ua lly
Is the load too hea vy? • Reduce the l oa d.
Does the l oa d vary largel y?
• Mi nimi ze the variati on of the load.
• Increas e capaciti es of the inverter and
the motor.
Is the input power l ack of pha se?
• Add an AC rea ctor a t the power input
side if us ing s ingl e-pha s e powe r.
• Check wi ring i f using three-pha se
power.
Motor
running
spee d too
hi gh or too
low
Are speci fi cations of the motor (pol es ,
voltage…) correct? • Confi rm the motor’s speci fi cations .
Is the ge ar ratio correct? • Confi rm the gea r ratio.
Is the setting of the hi ghes t output frequency
correct? • Confirm the hi ghest output frequency.
The motor
spee d can
not be
regul ated.
Are wiri ng for a nalog frequency i nputs correct? • Check wi ring a re correct if neces s ary.
Is the setting of operation mode correct? • Check the ope rati on mode of the
opera tor.
Is the load too hea vy? • Reduce the l oa d.
Has a na log frequency s i gnal been input?
*General Troubleshooting of In erter

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*Quick Troubleshooting of In erter

1
Inverter
Fault

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18
Inverterfault

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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.

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