Technical Manual SYP Rice Cake Machine Standard Model Shinyoung Mechanics / DP KOREA Rm. 602-29, 6F, Joyluck Town, 1138-1, Joong-dong, Wonmi-gu, Gyeonggi-do, KOREA Tel:82-32-346-5840 Fax: 82-32-346-5841 E-mail : world@new-pop.kr / joh1109@hotmail.com Website : www.new-pop.kr CONTENTS 1. OUTLINE -----------------------------------------------------------------Page 3 2. STRUCTURE ------------------------------------------------------------Page 3 3. NOMENCLATURE -----------------------------------------------------Page 4 4. SPECIFICATION -------------------------------------------------------Page 7 5. IMPORTANT THINGS TO KNOW BEFORE OPERATION ---Page 9 1) Installation 2) Raw materials 3) Adjusting pressure 4) Adjusting temperature 5) Decrease in temperature during the initial operation 6) Co-relation between pressure, temperature and rice cake 7) Adjusting Volumes 8) Manual test of hydraulic system in solenoid valve 9) Adjusting snack shape 6. OPERATION ----------------------------------------------------------Page 15 1) Before operation 2) Operation 3) After operation 7. TROUBLESHOOTING ----------------------------------------------Page 19 8. INSPECTION & OIL SUPPLY -------------------------------------Page 21 9. SAFETY ----------------------------------------------------------------Page 22 10. ELECTRIC DIAGRAM ---------------------------------------------Page 23 11. TOOLS & SPARE PARTS ----------------------------------------Page 24 1. OUTLINE SYP Rice Cake Machine produces round, square, or rectangular shape of grain cakes through self-feeding, compression, heating, swelling procedures with natural rice, brown rice and other whole grains and etc. In contrast to previous machine which could only use artificial rice, SYP Rice Cake Machine pops natural grains from all around the world with strong pressure so it could process most of the grains and does not create loud sound. With SYP Rice Cake Machine, you can create grain cakes that embrace the natural taste of grains. 2. STRUCTURE • Hopper : Containing raw materials • Feeding Part : Supplying the raw materials to Mould • Mould : Heating and Pressing the supplied raw materials • Hydraulic Part : Compressing Mould • Adjusting Temperature Part : Adjusting temperature of Mould • Micro Control : Making machine works in order • Switch Box : Machine operation • Frame : Fixing the upper structures in their places Relocation is easy for anyone with its compact size and wheels, especially for stores, shop-in-shop etc. 3. NOMENCLATOR * SYP8501 Hopper Mould Upper cover Pressure gauge Emergency button Lower cover Switch box PV AT SV OUT SV2 ALM SET 히 터 유압모터 운 전 예 열 하 강 저 고 속 도 두 께 Fan Frame 모 양 Wheel Outline(Pic 1) Upper block Upper mould Lower mould Guide post Extract cylinder Rising cylinder PV AT SV OUT SV2 ALM SET Screw for adjusting first pressure Pressure cylinder 히 터 유압모터 운 전 예 열 하 강 저 고 속 도 두 께 모 양 Power pack Oil cooler Internal Structure (Pic 2) Feeder Screw for fixing feeder Sensor Lever Spring Chain Key Valve for adjusting thickness (oil speed) Solenoid valve Cam drive motor Screw for adjusting second pressure * SYP4506, SYP2515 – SYP6060(S2) Hopper Mould Pressure gauge Upper cover Emergency button Lower cover Switch box PV AT SV OUT SV2 ALM SET 히 터 유압모터 운 전 예 열 하 강 저 고 속 도 두 께 모 양 Fan Frame Wheel Outline(Pic 3) Upper block Upper mould Guide post Guide Extract cylinder Rising cylinder PV AT SV OUT SV2 ALM SET Screw for adjusting first pressure Pressure cylinder Feeder Screw for fixing feeder Sensor Lever Spring Chain Key Valve for adjusting thickness (oil speed) Solenoid valve 히 터 유압모터 운 전 예 열 하 강 저 고 속 도 두 께 모 양 Power pack Oil cooler Internal Structure (Pic 4) Cam drive motor Screw for adjusting second pressure 3. NOMENCLATOR-Actual appearance SYP8501 SYP4506, SYP2515, SYP6060(S2) etc. 4. SPECIFICATION Specification SYP8501 Dia 85 * Thickness 10 SYP4506 Dia 45 * Thickness 8 SYP6060 (S2) 60 * 60 * Thickness 10 SYP9502 Dia 95 * Thickness 10 Standard Size SYP8501 360pcs/hour SYP4506 2,160pcs/hour SYP6060 (S2) 720pcs/hour SYP9502 720pcs/hour Capacity Power Consumption Hydraulic Motor 0.75Kw, 220V, 60Hz(50Hz) Drive Motor 25w Heater Hydraulic SOL/V SYP8501 1.2Kw SYP4506 SYP6060( S2) 2.8Kw SYP9502 2.8Kw - - Remark Thickness adjustable 4. SPECIFICATION Specification Hydraulic Pump 8.5L/min Basic Pressure 40kg/cm2 Supercharg ed Pressure MAX 150kg/cm2 SYP8501 SYP4506 Dimensions Net Weight SYP6060 (S2) Remark Adjust this according to the raw material and temperature D650 * W510 * H1,480 D650 * W510 * H1,500 (mm) SYP9502 D650 * W510 * H1,560 SYP8501 180kg SYP4506 190kg (Including Hopper) (Including Hopper) SYP6060 (S2) 190kg SYP9502 220kg 5. IMPORTANT THINGS TO KNOW BEFORE THE OPERATION 1) Installation Move the machine to your set-up place and press down the locking lever, and then fix the wheels at the place you will set-up the machine. Please check if the grounding (earthing) is appropriately done. 2) Raw Materials Wheel (Pic 5) You may use normal white rice, brown rice, barley and mixed grains for your grain cakes. As your recipe, you can mix flavors like natural sweetner or salt, and it should be melted into the water, and the flavored water must be absorbed into the grain after longer than 12 hours after mixing. Usual moisture of grain is about 14% - 18% generally, and for higher percentage, you can mix more water with the grain to soak the water. For exemple, in case of 2% increase from 14% to 16% of 10kg rice, you can add 200g(200cc), 2% of 10kg to the rice and soak it. * 10,000g X 0.02(2%) = 200g(200cc) => Increase of 2% from 14% to 16% in 10kg. 3) Adjusting Pressure Adjusting pressure is one of the most important options for the taste and popping condition of grain cake. There are the first pressure and the second pressure. The first pressure is for the basic operation of the machine and popping condition of grain cake is decided by the second pressure, giving a supercharged pressure to raw materials in mould. Therefore, you do not need to control the first pressure. You may control the second pressure a little according to the raw material and humidity. Screw for Adjusting Pressure <Backsid of Machine> (Pic 6) * How to adjust the pressure Please loose the locked-nut of screw for adjusting pressure. Pressure goes up if you turn the screw to clock-wise, and pressure goes down if the screw is turn anti clock-wise. After increase of temperature of mould, the first pressure put pressure on the grain cake. Upon increase of temperature of mould, the second pressure rises and then the second pressure falls gradually. * PRESSURE GAUGE You can check the present pressure with the pressure gauge as the photo. It shows the 1st pressure about 40Kg/cm2 when you start, and about 120 – 150 Kg/ cm2 when it pops. When you adjust the pressure with the backside nuts, you can control the pressure with the degrees on the pressure gauge. The pressure gauge has a valve, which can open and close the gauge. When you need to check the present pressure on the gauge, you open the valve turning un-clock wise, and when you complete to set or check the pressure, please close the gauge to use it longer. You can check the present pressure with the gauge. 1st pressure is about 40Kg/ cm2, and 2nd pressure(when popping) set about 120 – 150Kg/ cm2. When you adjust the pressure, you can check the present pressure with this. Open: turning un-clock wise. Close : turning clock wise. After temperature set, please close the valve to use the gauge longer. * Emergency Stop / Restart In case of emergency situation, for example, you find something inside of the moulds, or when you need to stop the machine, you can stop the machine with Pump Off, or Operation Off in the Switch Box. Also you can stop the machine immediately to push the “Emergency Stop Button”, located in front of the Pressure Gauge as the below photo. Push the button, the machine stops immediately. When you want to restart the machine, you can push with turning to the light, then the button goes up and the machine restarts. At this time, you should take care of the all conditions of the machine because the heater is still on. * Stop : Push the button. * Re-start : Push and turn to light as the arrow on the button. * After re-start, you should check all the conditions of the producing(temperature, and pressure as per the rice cake condition) 4) ADJUSTING TEMPERATURE This device controls and adjusts temperature of inner side of mould. There are upper mould and lower mould. Each mould has 2 heaters. The set temperature of each machine is: (SYP8501=240°C, SYP6502, SYP4570, SYP4506=260°C) and you can adjust the temperature slightly according to raw material and humidity. PV Process-value display(red) AT OUT SV2 SV Set-value display(green) ALM SET Set-value increment key Set-value decrement key Setting digit shift key Set completion key Thermometer (Pic 7) ※ How to change the temperature ① Press ◁ -> You can see the flickering number of current temperature (last figure) ② If you want to change the figure of temperature, please press ◁ While your figure is flickering, you can change the temperature by pressing △ or▽ ③ If you need to change the figure of temperature again, please repeat ② ④ You can finish the changing temperature by pressing SET(No more flickering). (Example) If you want to change 240°C (current temp) to 235°C ① Press ◁ ② Set 5 by Pressing △ ③ By pressing ◁, next figure is flickering(10th) and then set 3 by pressing ▽ ④ Press SET ※ Caution : Thermometer have various functions, and already is set at good condition so if unnecessary, do not manage the buttons of thermometer. 5) DECREASE IN TEMPERATURE DURING THE INITIAL OPERATION Note) Upper case is normal phenomenon, so you do not need to adjust temperature separately. 6) CORELATION BETWEEN PRESSURE, TEMPERATURE AND RICE CAKE Rice Cake Condition Temperature Pressure Color Shape and Thickness Up Turning Brown Getting Thicker Soft and scorched taste Down Turning White Getting Thinner Less popping and hard Up Turning Brown Getting Thicker Taper at periphery Soft and scorched taste Down Turning White Getting Thinner Less popping and hard Taste 7) ADJUSTING VOLUMES (TIME TO PRESS, THICKNESS AND SHAPE OF CAKE) Operator can adjust ① Pressing Time, ② Thicness of Cake, ③ Shape of Each Side of Cake through the adjusting handles under the operation switches. ① Time to Press : Speed Adjustment ADJ 5 10 3 0 90 FIX 30 20 80 70 LOW 60 HIGH 4 You can adjust the pressing time to control the speed of the producing. The standard time is set in 10 sec. for one pressing(cycle), and It can be adjusted about 8 - 15 sec through the handle adjustment. Clock-wise turning makes slower, and unclock-wise makes faster. 50 4 0 ② Thickness of Rice Cake ADJ 5 4 0 90 50 4 0 60 6 10 FIX 30 20 80 70 You can adjust the thickness of rice cake by the thckness through the handle. Clock-wise turning makes thicker, and unclock-wise thinner. ③ Shape of Each Side ADJ 4 10 3 2 0 90 FIX 30 20 80 70 You can adjust the shape of each side of cake. Turning clock-wise, makes the inner mould go deeper, and flat below side, and unclock-wise makes the inner mould go shalower and flat upside. 60 50 4 0 8) MANUAL TEST OF HYDRAULIC SYSTEM IN SOLENOID VALVE Operation lamp Moulds down PUSH Core mould down PUSH PUSH Moulds up PUSH Pressure PUSH Core mould up Solenoid Valve (Pic 8) 9) ADJUSTING SNACK SHAPE(SYP4506) Shape 28 21 24 Feeding Plate 24 Volume on PCB Press Time(S.T.D) : Max Thickness 5.0 ±? 5.0 ±? 0.0 ±? Core Dept 2.0 ±? 2.0 ±? 2.0 ±? Temperature 260℃ ±? 240℃ ±? 225℃ ±? Second pressure 150kg/㎠ 150kg/㎠ 70kg/㎠ Volume Note : As per dept of core, surface shape of snack is changed, in case of too deep, the popped rice can be leaked between core and mould(Value of depth adjustment can be little different from each machine). PV 6. OPERATION Temp controller SET HEATER 1) BEFORE OPERATION ① Turn on hydraulic motor switch ② Turn up finish switch to close top and bottom mould ③ Turn off hydraulic motor switch ④ Turn on heater switch to pre-heat the machine. ⑤ Put raw materials into hopper. ⑥ Be ready to get the grain pop AT SV OUT SV2 ALM ON OFF Heater switch ON OFF Hydraulic motor switch PUMP OPERATION ON OFF MANUAL UP LOW HIGH Operation switch Preheating switch(up) Downward switch(down) Speed adjusting volume SPEED Thickness adjusting volume THICKNESS Shape adjusting volume SHAPE Operating Switches (Pic 9) 2) OPERATION (When mould temperature reaches setting temperature) Preheating period-SYP8501: 10~15 min. SYP4506 and Others : 30 min. ① Turn on hydraulic switch ② Turn down cleaning switch to lower down the bottom mould ③ When the pre-heating temperature reaches set temperature, turn the operation switch ④ Grain cakes will be produced from the machine. Note) At first, while the temp of the machine is falling, the machine can make more thinner grain cake than what you expect to get. But after that, while the temp of the machine is stable, the machine will make the grain cake exactly what you wanted Process (Pic 10) • Photos with Start - OPERATION 1-1. The moulds are closed for preheating 1. Turn on the Pump and Manual Up to close the moulds before Preheating 2-1. Manual Down Before Start. 2. Turn off the Pump and Heater On, and waiting for the preheated to the set temperature. 3. After preheated, Pump On, and Operation On to start producing (Check the raw materials in the hopper) 4. Then, the Supplying Plate comes forward to supply the rice on the moulds, and popping, and producing the rice cakes. • Photos with Stop 1. Heater Off 2. Operation Off, JUST AFTER POPPING, before another supplying of the rice. Then Cleaning in this condition(All surface of the moulds) 4. After cleaning on the all surfaces of the moulds, Pump On, and Manual UP & Down several time, to clean the surfaces again. Cleaning is very important 3. Pump Off(All Off) 5. After all cleaning, Manual UP to close the moulds, and Plug Out. Tomorrow, you do not have to close the moulds before preheating at this condition. 3) AFTER OPERATION ① Turn the heater switch off. ② Shortly after descent of mould, turn the operation switch off. ③ Take the rice cake in the mould out. ④ Remove the alien substance and dregs of rice cakes with scrapper and wire brush and cleaning the surface of the moulds by dry cotton cloth. ⑤ Clean and remove the alien substance and dregs of upper and lower mould. Cleaning (Pic 11) ⑥ Close the mould by Manual Switch. ⑦ Turn the hydraulic motor off. ⑧ Remove the alien substance and dregs of lower mould, and pull out the plug. ⑨ Clean around the machine. (after using the machine, heater switch MUST BE TURNED OFF) 7. TROUBLESHOOTING PROBLEM 1) Machine does not work CAUSE & CONDITIONS SOLUTIONS Hydraulic motor is out of order Check the power supply, switch, motor in order Emergency Button On Push and turn colock-wise to off Supplying Plate(for raw material) does not move backward fully(Sensor is not in perception). - Check the spring. - Move the supplying plate back fully. If there is any substances between plate, remove it after turn operation & pump off, and on again. -Refer to No. 8 Inspection 2)The shape of rice cake is not good 1) Not right temperature Adjust temp properly(Refer to No. 5-(4)). 2) Not right pressure Adjust 2nd pressure properly in 70Kg/㎠-150Kg/㎠ as per the raw material(Refer to No. 5-(3)). 3) Depth of inner core Adjust core depth volume(Refer No. 5-(7)-③). 4)Alien substances on the surface of moulds. Clean the surface of moulds. Thermometer, SSR or temp. sensor out of order. Replace it 4)The color of rice cake is not equal Heater is out of ordero(Not heated) Che ck the wire and heater and replace it. 5)Electric shock Earthing error. Earthing properly. 6) Breaker in malfunctioning Short circuit 1) Moter and heater check(after seperation wire) 2) Wire check(after skin off) 3) Remove aliens on heater connection part 3)Temperature is not adjusted automatically Note : - In case the Supplying Plate does not go back fully, the machine stops(backward sensor (red lamp : below the Supplying Plate) check. - In case of machine stop due to the S. Plate backward problem, turn off the operation, and pump, and remove the reason(spring, or alien between plates), and turn on the pump and operation, then, the S. Plate goes forward and backward. You can find the red lamp on. 8. INSPECTION & OIL SUPPLY Terms Content Remark After whole operation, remove the substance of upper and lower mould. Check the cooling fan. If substance remains, it can be stick to the mould, and snack is not good. Weekly Disassembling upper cover and cleaning inside of it. ♦ Cleaning alien substance on the surface of the moulds. Remove the substance guide post. Refer to PIC. No. 11. Monthly Disassembling lower cover and cleaning inside of it. Remove the substance of oil cooler. Checking the tension of chain, and loose of setscrew on motor spracket. Cleaning surface of the supplying plate. Daily Yearly Changing the oil for Hydraulic operation (1 year or 3,000 hours) Refer to PIC. No. 12. Hydraulic Oil : ISO VG 46 (Viscosity No. 46 for 4 Seasons) Screw ◇ Cleaning of Oil Cooler In case it has dirt or alien substance, the oil can be overheated due to low function. You must clean it regulary as below. 1) Release the screw(Refer to PIC. No.12) and separate the fan. 2) Remove the alien substance on the cooler. (By air compressor or vacuum cleaner) 3) Assemble the fan. Oil Cooling Fan (Pic 12) 9. SAFETY Safety precaution is the most important thing, and please follow the safety guideline. 1) When mould rise, do not place your hand between two moulds. 2) Do not touch the mould and upper block with bare hands 3) Upper cover and safely cover should be assembled before operation. 4) When cleaning, turn the heater switch off. (Please be careful the short circuit of connecting part of heater line) 5) When the Supplying Plate stops between moulds, you should turn off the machine(Operation, and Motor), and pull back the Supplying Plate. Caution on Mould (Pic 13) 10. ELECTRIC DIAGRAM Temp/C R1 R T R 1 6 2 7 3 8 4 9 5 10 1 DC 4-32V 2 RED S BLUE 1 SSR 4 2 Heater T MS MS 5 T R2 6 SOL1 SOL3 SOL4 Cam Drive 14 백 갈 흑회 SOL2 7 M SOL5 Hyd Moter 7 T POWER 15 T 18 UP,DOWN Ry1 Ry2 SOL1(UP) SOL2(PRESS) 16 T 22 T 20 13 EJ,POP PRESS Ry3 T MOTER Ry4 Ry5 Ry6 SOL4(EJECT) SOL5(POPPING) MOTER TRANS 12V INVERTER SOL3(DOWN) 0 12 PRESS TIME (STD : MAX) VR1(SPEED) 30 32 31 (THICKNESS) VR2 VR3(SHAPE) 30 33 31 30 34 31 (READY) SNSR1 (SAFETY) SNSR2 (AUTO) SW1 35 37 36 35 38 36 39 40 (MANUAL) (EMERGENCY) SW2 SW3 41 42 43 44 45 Black Brown U V W R T R T 7 T 5 Blue EM 6 Start Sensor M M Hyd Fan 0.15A Heater 750W R T Electric Diagram (Pic 14) VR VR VR Speed Shape Thickness Up Down Manual Operation Safty Sensor OPTION 11. SPARE PARTS No Part Name Specification Quantity 1 Tool Box 1 pc 2 Wrench SET 1 pc 3 Spanner & Nut Wrench 8 1 set 4 10 1 5 13 1 6 17 1 7 Monkey Spanner 250m/m 1 pc 8 Wrench HEX 14 1 pc 9 Driver + 150m/m 1 pc 10 Driver - 150m/m 1 pc 11 SSR(Solid State Relay) 1 pc 12 Relay 2pcs 13 Heater 1pc 14 Temperature sensor 1 pc 15 Pressure Gauge 1pc 16 Temperature controller 1 pc Remark M16 Wrench for bolts Provided when ordered separately Tel:82-32-346-5840 Fax: 82-32-346-5841 E-mail : world@new-pop.kr / joh1109@hotmail.com Website : www.new-pop.kr Shinyoung Mechanics / DP KOREA Rm. 602, 6F, Joyluck Town, 1138-1, Joong-dong, Wonmi-gu, Gyeonggi-do, KOREA
