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SYP English Manual(2020)

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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
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