Service Manual - Wholesale Restaurant Equipment
Contents
1. P42 6 3 Failure Diagnosis P43 7 CIRCUIT DIAGRAM P44 1 SPECIFICATIONS 1 1 Introduction This service manual is written for the person who are usually engaged in service and maintenance as a professional There are explanations about the structure of chest type robot SUKETTO and about the way to check and to adjust each section of the machine Use this manual with Operational Manual and Service Parts List for correct comprehension of the machine and for correct servicing 1 2 Specification Chest type Robot SSG SCS Sushi 0 1800 pieces hr 20g for each 1 Omusubi 0 750 pieces hr 100 g for each 1 Sushi Approximately 16 25g 2 Omusubi Approximately 50 100g 2 Approximately 12 litters of sushi rice N A AC 100 V AC 240 V 50 60 Hz Operating State maximum 100 W Different in different places Diameter 445 mm Height 390 mm approximately 13 kg Special Stand available separately charged 1 The output varies depending on the rice amount to be set 2 The amount changes with the rice temperature in the hopper 3 The time value is the time interval that passes while the rice temperature decreases voluntarily from 45 C 113 F at the start to 36 C 96 8 F at the end with 6kg rice in the hopper with the lid 2 CAUTIONS FOR SAFETY OPERATION 2 1 Warning For Safety Ope2. Table4 Basic Parameter Preset Values For Sushi Mode Parameter Parameter Name Unit Setting Initial Number Range Value 1 Vertical Screw Speed 0250 a 2 Horizontal Screw Speed 0 250 b 3 Shutter Speed 0 250 230 4 Shutter Open Position 1 pulse 0 127 36 5 Shutter Close Position 1 pulse 0 127 40 6 Horizontal Screw on dly 10 msec 0 1023 0 7 Rice Amount on dly 1 pulse 0 1023 65 8 Basic Compression 1 pulse 0 1023 0 9 Compression Motion 1 pulse 0 1023 25 There are 3 operation modes of the production speeds for Sushi Mode They are low speed middle speed and high speed The values of parameter 1 and 2 are 88 a and 80 b for speed motion 131 a and 120 b for middle speed and 188 a and 188 b for high speed Table5 Basic Parameter Preset Values For Omusubi Mode Parameter Parameter Name Unit Setting Initial Number Range Value 1 Vertical Screw Speed 0 250 a 2 Horizontal Screw Speed 0 250 b 3 Shutter Speed 0 250 230 4 Shutter Open Position 1 pulse 0 127 36 5 Shutter Close Position 1pulse 0 127 40 6 Horizontal Screw on dly 10 msec 0 1023 0 T Rice Amount on dly 1 pulse 0 1023 150 8 Basic Compression 1 pulse 0 1023 300 9 Compression Motion 1 pulse 0 1023 50 There are 2 operation modes of the production speeds for Omusubi Mode They are low speed middle speed The values of parameter 1 and 2 are 148 a and 148 b for low speed an
3. Terms in Table 2 a Fan Temp The machine controls the cooling fan to be lower than the set value If the set value is equal to 10 then the machine keeps turning off the cooling fan and does not control it b Rice Stuffing Judging Level This value is used as a baseline criterion to judge if the operation is in rice stuffing status The machine diagnoses the motion status of Vertical 19 Screw and Horizontal Screw as rice stuffing if the output speed pulse of each Screw is less than the criterion for 500 ms or more c Torque Reducing Rate Vertical Screw Rated Torque d D f Horizontal Screw Rated Torque The machine reduces the motor speed by Torque Reducing Rate if the number of the output pulses of Vertical Screw Motor Torque keeps higher than Vertical Screw Rated Torque for more than 300 ms or that of Horizontal Screw Motor Torque keeps higher than the set value Horizontal Screw Rated Torque for more than 300 msec It starts again to monitor the torque pulse number after 1200 msec from the speed reduction and the machine halts if the torques keep higher than the rated torques for more than 300 ms judging the machine is in the state of rice stuffing Current Reducing Rate Maximum Current The machine reduces the motor speed by Current Reducing Rate if the total current of vertical screw motor horizontal screw motor and shutter motor which is the total value of the driver input currents to be ac
4. 2 2 and so equals 22 in Figure 3 Figure 4 shows the expression way of Parameter Mode Selection 1000060000 2 N LED of LED of Mr a oe et Softness Switch Firmness Switch Figure 3 10 digits with 10 Bar Indication Figure 4 Lamp Expression of Parameter Mode The Parameter Mode is expressed by LED blinking 4 6 4 2 Parameter Setting Operation Indicator initially shows a parameter number when the operation state is changed into Parameter Mode by inputting a password from stop status of normal condition Then select a parameter number with pushing V or A Switch Next set the parameter value into the memory of corresponding the parameter number with keeping pushing holding Softness Switch and pushing V or A Switch During keep pushing Softness button Indicator Bars shows the value of the parameter 4 6 4 3 Finish Parameter Mode Refer to Figure 2 Just push Firmness Switch in order to change the operation mode to normal mode stop state from the parameter mode 16 4 6 5 Setting Parameters 4 6 5 1 Setting BASIC PARAMETERS There are 5 basic data tables memories for 5 basic parameter sets To enter Basic Parameter Mode input A V A V A V A V by pushing A and V buttons sequentially and quickly When the mode is changed to the mode Softness LED blinks JUUUUBU EL fo 2 22 2 2 EEE LED of Softness Switch Figure 5 Basic Parameter Mode blinks during the mode Table 1 shows units and setting intervals for Basic
5. Parameters Table1 Basic Parameters and Setting Intervals Parameter Parameter Name i Setting Number Vertical Screw Speed 0250 Horizontal Screw Speed 0250 Shutter Speed 0250 Shutter Open Position 1 pulse 0127 Shutter Close Position 1 pulse 0 127 Horizontal Screw on dly 10 msec 01023 Rice Amount on dly 1 pulse 01023 Basic Compression 1 pulse 01023 Compression Motion 1 pulse 01023 O DINSIOIUNRIUVU NR Terms in Table 1 a Vertical Screw Speed Horizontal Screw Speed and Shutter Speed and other 2 Screw Speeds Set values for those above are used for driving those screw motors with the set values Definition On dly or off dly timer are defined as the delay time for motions from when the shutter is opened or closed respectively 17 b Shutter Open Position or Shutter Close Position The set value means the on dly motion amount from the time that Shutter Sensor turns on or off c Horizontal Screw on dly It defines the unit motion amount of on dly motion for Horizontal Screw The on dly value is used for the on dly motion d Rice Amount on dly It defines the unit motion amount of on dly motion for Rice Amount The on dly value is used for the on dly motion e Basic Compression It is the basic pulse number for compression f Compression Motion It is the basic pulse number for the unit motion for compression 4 6 5 2 SETTING BASIC PARAMETERS SETTING COMMON PARAMATERS To enter th
6. all set values back just as they were Horizontal Screw and Hopper Screws e Check the directions of the rotations are correct Check the status of conveying rice is normal and smooth Shutter Base Part Check the status and timing of the motion is normal Confirm if the engagement between Shutter Blades and Shutter Crank is normal Confirm if the Shutter can cut rice well Confirm if the sensibility of sensors are normal Vertical Screw Part e Check the rotation direction of the vertical screw is correct e Check the conveying status of rice is normal Safety Sensor Check the safety sensor works normally and the machine comes to a stop when sensors detect a material body Other e Check unusual sound is not generated from each moving units 4 SUPPLEMENTARY EXPLANATIONS 4 1 Supplementary Explanations a Automatic Cooling Function Cooling Fan starts to work when the inner temperature becomes more than the preset value b About Softness and Firmness Setting the values of Softness and Firmness changes the time interval of the vertical screw motion while shutter is closed There are 2 kinds of sushi cake condition One is firm and the other is soft Usually the firm sushi cake is used with rolling seaweed sheet around it and the soft sushi cake is used for usual sushi Nigiri Sushi The condition is easily changed only with setting once T
7. cables just as they were locate them in the original position b Removal of fixing screws M4 x 10 W SEMS M3 x 10 W SEMS M4 X 10 W SEMS 31 c Removal of Controller Chassis 3 Taking out Controller Chassis from Base Section with taking care of not pulling the cables of DC Blushless Motor Driver 5 1 3 Control Panel Control Box a Pulling out Control Panel The photograph above shows Pull out status of Control Panel Control Panel must be pulled out before taking out Vertical Drive Gear Box 32 b Removal of Fixing Screws M2 6 x 8 P TIGHT Remove M2 6 screws with a driver No 1 c Caulking Fill silicon caulking material into the ditches spaces when the part is reassembled after gi disassembling The connection edge of the wiring is filled with silicon compound in order to protect water intrusion into there After disassembling it refill the compound again 33 d Removal of Control Board Remove Control Panel as shown above 5 1 4 Horizontal Drive Gear Box M4 x 14 P TIGHT a Removal of Drive Gear Drive Gear clockwise Drive Gear counter clockwise Take out 3 Drive Gears counter clockwise 2 pcs clockwise 1 pcs and 2 Tight Screws 34 b Removal of Fixing Screws M4 x 14 P TIGHT Pull up the cable clamp to unbind and loose cables c Removal of Horizontal Gear Box The Photograph of Horizontal Drive Gear Box removed 35 5 1 5 Vertical Driv
8. codes which are bound with plastic straps moving parts tubing parts made of dielectric material and so on e Confirm the safety is secured by inspecting whether deteriorated parts around the serviced region are in the machine or not and whether all electric cables bolts and nuts which were dismantled for servicing are in the correct locations as they were 3 HOW TO INSTALL 3 1 Caution During Transportation Handle parts with care because almost all parts in the machine are made of plastic and strong physical shock may cause the breakage 3 2 Installation and Test Operation a Installation Environment Appearance Check and Removing Fitting Check Inspection Part Inspection Item Installation Environment Avoid the place where the machine temperature raises up with a thermal irradiation emission Avoid the place where the vapor exposure is on the machine Avoid the place where the machine have water condensation on it with high humidity Avoid the place where the machine is exposed by water near a sink Confirm if the machine is on the level Appearance e Check all the parts are fitted in the machine and all the attachments come with it Hopper Part Check hopper part can be disconnected and fitted Check the assemble parts have laxation when all the parts are assembled Horizontal Screw Check the part can be removed and fitted Check no scratch or fl
9. detection for example Rice Detection Sensors 4 detects rice if Rice Detection Sensors 6 does not detect the rice before it then the machine comes to a halt judging the status as an abnormal situation b How to Recover The machine starts to work after eliminating all cause of the abnormal sensing Without the elimination the machine can not be recovered 27 5 DISASSEMBLY AND ASSEMBLY OF CONTROL SECTION AND DRIVING SECTION 5 1 Disassembly and Assembly Bottom Panel can be removed from Main Body by take out all screws as shown below 5 1 1 Base Section a fixing and removing screws M4 x 10 W SEMS SCREW M4 x 14 P TIGHT SCREW M4 S tight screw is used for tighten up the panel on the bottom section of Main Body M4 P tight screw is a self tapping screw 28 b Removal of Ground Cable and Connectors Removing THE Connector Removing Earth Cable Removing Gonnector M4 x 10 W SEMS c Removal of Base Section Photograph of the Rear of Base Section Earth Cable and Connectors 29 d Removal of Main Switch Box Power Switch Box At First loose 4 P Tight Screws M3 x 12 P TIGHT e Removal of Main Switch Pull Out TOOL Molex 57031 6000 only for connector pins of the connector must be used when Main Switch is exchanged 30 5 1 2 Controller Chassis a Removal of Connectors Confirm the pathways of all electric cables beforehand When they are attached again place all the
10. power cord when the machine is unplugged Pulling the cord out of the electric outlet may result in the damage of the cord and or the plug and result in electrical shocks short circuits and fire Turned off and unplug the machine before disassembling assembling and or cleaning the parts in the maintenance Maintenance of the machine with the power applied may result in accidental injury Do not use the machine when the cords and the attachment plug are deteriorated and heated and when the plug outlet connection is loose Do not break the cords and do not modify them Bending of the cords straining of the cords twisting of the cords nipping of the cords binding of the cords and putting heavy things on the cords may result in the breakage of the cord fire and electrical shocks Operate only with the supply voltage of 230VAG Different voltages supplied may result in fire and electrical shocks Do not move the machine in operation Moving it in operation may result in injury Place the machine in a proper stable and safe place for example a stable cart with stoppers stand or table for the operation Unstable setting of the machine may result in injury by its fall Pull out the attachment plug from the outlet when the machine is not used The failure of observing the instruction may result in electrical shocks due to the deterioration of the insulation and fire due to electrical leaks Make sure that the transparent plast
11. Firmness Mode The mode can be determined by which switch is selected The LED lit on Softness switch or Firmness Switch determines the actual mode of compression If LED on Softness switch lights on the mode is Softness Mode To change into Compression Mode push Softness switch and AorV Switch together or push Firmness switch and A or V switch together Compression Mode lasts only when Firmness switch or Softness switch is pushed In Compression Mode the location of lighting in Indicator set value of the compression rate is controlled with pushing AorV switch up to 10 by one step The relation between Softness Compression and Firmness Compression is expressed by 1Compression in Softness Mode Compression in Firmness Mode lt 10 Note The mode to be set is effective after the shutter is opened 4 4 SSG SCS Setting Function and Indication in Detail 4 4 1 Rice Amount Setting and Rice Detection Sensor There are 6 Rice Detection Sensors vertically arranged sensors on the side of the shutter blade Rice Detection Sensor 1 2 3 4 are used for Omusubi Mode and Rice Detection Sensor 4 5 6 are used for Sushi Mode respectively Setting the rice amount and selecting operation mode determine actual sensors for control And Amount of Screw Motion amount of on dly motion is used for stopping screw motion and cutting timing after the top sensor detects a rice cake that moves up to the determined sensor level On dly motion is defined by On
12. Service Manual Chest Type Robot SSG SGS SUKETTO SSG SUS Specified for Sushi Cakes V WE LOVE RICE SUZUMO CONTENTS 1 SPECIFICATIONS P3 1 1 Introduction P3 1 2 Specification P3 2 CAUTION FOR SAFETY OPERATION P4 2 1 Warning For Safety Operation P4 2 2 Precaution For Servicing P7 3 HOW TO INSTALL P8 3 1 Caution During Transportation P8 3 2 Installation and Test Operation P8 4 SUPPLEMENTARY EXPLANATIONS P10 4 1 Supplementary Explanations P10 4 2 SSG SCS Operation Status Transition P11 4 3 SSG SCS Setting Function and Indication P12 4 4 SSG SCS Setting Function and Indication in Detail P13 4 5 Compression and Compression Motion P14 4 6 Parameter Mode P14 4 7 SSG SCS Safety Function P26 5 DISASSEMBLY AND ASSEMBLY OF P28 CONTROL SECTION AND DRIVING SECTION 5 1 Disassembly and Assembly P28 5 2 Other Instructions P40 6 TROUBLE SHOOTING P41 6 1 Self Diagnosis Function P41 6 2 Blushless Motor Driver Alarm
13. Switch The compression motion is defined as the motion of Vertical and Horizontal Screw by the amount after a rice cake is detected and Shutter is closed except for stopping by Start Stop Switch and by time out error The amount of motion is determined by The amount of motion compression rate 1 the compression motion unit pulse number the basic compression motion pulse number one of the basic parameters one of the basic parameters Regarding parameters are referred to the below 4 6 Parameter Mode Sushi Chef SKETTO has driving parameters which define how the machine works in usual situation and how it reacts in operation where the motion is in unusual situation or in some situation For example Vertical Screw Speed Shutter Speed Basic Compression Time out Time and etc There are 2 kinds of parameters one is called basic parameters and the other is called common parameters 4 6 1 BASIC PARAMETERS Total 5 Sets Sushi Mode 3 Sets and Omusubi Mode 2 Sets Basic Parameters are set respectively for 5 operation patterns Sushi Mode Operation Pattern 1 Sushi Mode Operation Pattern 2 Sushi Mode Operation Pattern 3 Omusubi Mode Operation Pattern 4 and Omusubi Mode Operation Pattern 5 In Sushi Modes and Omusubi Mode only the differences are the speed values of Vertical Screw and Horizontal Screws There are 5 memory regions for storing 5 parameter sets in the machine Operation Pattern can be selected by setting Prod
14. aw is on the part Hopper Screws Check the part can be removed and fitted Check all the gears are engaged adequately Check no scratch or flaw is on the parts Hopper Bearings Side Plate Check the part can be removed and fitted Check no scratch or flaw is on the part Vertical Screws The joints of the parts can be removed and fitted Check no scratch or flaw is on the part Vertical Screw Cylinder Check the part can be removed and fitted Check it is fixed firmly after fitting Check no scratch or flaw is on the part Shutter Base Part Shutter Base Part e Check Shutter Base Shutter Blades and Shutter Crank can be removed and fitted Check they are fixed firmly after fitting Handle Check the part can be removed and fitted Check no scratch or flaw is on the part Absorption Holder e Check Water Absorption Sheet and Absorption Holder can be removed and fitted Check no scratch or flaw or deformation is found on the parts b Operation Check Inspection Part Inspection Item Control Panel Check Operation Lamp lights up e Check the rice amount is shown on Indicator and if it is controllable e Check softness and firmness are shown on the Indicator and if they are controllable e Check the softness and firmness can be changeable with adjustment of the rice amount After checking the above put the
15. d 185 a and 185 b for middle speed 24 Table6 Common Parameter Preset Values Parameter Parameter Name i Setting Initial Number Range N A 10 80 N A 0 200 N A 10 80 Fan Temp 10 80 Rice Stuffing Judging 1 200 Level Torque Reducing Rate 0 100 Vertical Screw Rated O 15 Torque Horizontal Screw Rated O 15 Torque Current Reducing Rate 1 0 100 Maximum Current 0 1A 0 100 Operation Mode Change 0 2 Motor Rotation Direction 0 7 Shutter Open on dly 10 msec 0 1023 Shutter Close on dly 10 msec 0 1023 Initial Timeout Period 1 sec 0 300 Sushi Ordinary Timeout Period 1 sec 0 300 Sushi Initial Timeout Period 1 sec 0 300 Omusubi Ordinary Timeout Period 1 sec 0 300 Omusubi Shutter Timeout Period 10 msec 0 1023 Program Version 0 999 Production Counter 0 999 Upper 3 digit Production Counter 0 999 Middle 3 digit Production Counter 0 999 Lower 3 digit Selection of the Way of Operation Mode Change Refer to the previous contents in this Service Manual for changing parameters 25 4 7 SSG SCS Safety Function Safety Function is halt functions to protect an operator against a hazardous situation 4 7 1 INNER LID The machine can not be operated without Inner Lid Also the machine comes to a halt when Inner Lid is taken out or slid from or on the top of Upper Hopper Those behaviors are a parts of the safety function In the cas
16. dly amount on dly motion the amount of on dly unit pulse On dly motion is finished if the next sensor toward the top is ON detect i i i i i i i i i i the rice cake during the on dly motion dly is the abbreviation for the word delay On dly is defined as a time that some motion is started after a related sensor turns ON Rice Amount on the indicator Decrease Increase gt Table 3 The Relationship between Rice Amount Indication Rice Detection Sensor and on dly Motion Sushi Mode won 2 3 slel7 elelo Detection Sensor Detection Sensor 6 Detection Sensor 5 Detection Sensor 4 on dly motion 0 1 2 0 1 2 0 1 2 Bottom Top Table 4 The Relationship between Rice Amount Indication Rice Detection Sensor and on dly Motion Omusubi Mode toe lilelelslslelrislsje Detection Sensor Detection Sensor 4 Detection Sensor 3 Detection Sensor 2 on dly motion 0 1 2 0 1 2 0 1 2 Bottom Top There are six rice detection sensors and they are used as safety sensors for detection of a material body The top sensor is Rice Detection Sensor 1 and the bottom sensor is named Rice Detection Sensor 6 as explained later 13 4 5 Compression and Compression Motion There are two kinds of compression rate soft compression rate and firm compression rate The relation between them is expressed by 1 Soft compression Rate lt Firm compression Rate 10 It is possible to select set values by Softness Switch and Firmness
17. e Common Basic Parameter Mode input A A A V A V V V by pushing A and V buttons sequentially and quickly When the mode is changed to the mode Firmness LED blinks UU GUE i 29 28 57 28 p5 94 23 22 51 20 LED of Firmness Switch Figure 6 Common Parameter Mode blinks during the mode 18 Table 2 shows units and setting intervals for Common Parameters Table2 Common Parameters Parameter Parameter Name Number N A Setting Range 1080 N A 0 200 N A 10 80 Fan Temp 10 80 Rice Stuffing Judging Level 1 200 Torque Reducing Rate 0 100 Vertical Screw Rated Torque 0 15 Horizontal Screw Rated Torque 0 15 OI DM IN G JOTKA VID Current Reducing Rate 1 0 100 Maximum Current 0 1A 0 100 Operation Mode Change 0 2 Motor Rotation Direction Q 7 Shutter Open on dly 10 msec 0 1023 Shutter Close on dly 10 msec 0 1023 1 1 1 1 1 1 OTRA VOID o Initial Timeout Period Sushi 1 sec 0300 Ordinary Timeout Period Sushi 1 sec 0 300 Initial Timeout Period Omusubi 1 sec 0 300 Ordinary Timeout Period Omusubi 1 sec 0 300 Shutter Timeout Period 10 msec 0 1023 Program Version Production Counter Upper 3 digit Production Counter Middle 3 digit Production Counter Lower 3 digit Selection of the Way of Operation Mode Change
18. e Gear Box a Removal of Vertical Screw Joint and Shutter Spring Shutter Springs V Rings Vertical Screw Joint First take out Shutter Springs and V rings and then remove Vertical Screw Joint turning it counter clockwise b Removal of Connectors Remove the cables which are connected to DC Blushless Motor Take out 2 connectors from Controller Chassis 2 36 c Removal of Fixing Screws Do not remove the VG crews M4 x 14 P TIGHT Keep in mind that 2 screws are not removed d Removal of Vertical Drive Gear Box The groove for placing _sensor fibers The Photograph of Vertical Drive Gear Box removed Apply Shinetsu Silicone Oil G501 Silicon Grease to the bearings Do not use other grease 37 5 1 6 Controller Chassis 2 a removal of connectors Take out 4 connectors of the DC Blushless Motor Driver at 4 different locations b Removal of Fixing Screws M4 x 14 PTIGHT 38 c Removal of Control Chassis 2 The Photograph of Controller Chassis 2 removed Do not drag Controller Chassis 2 forcibly because fiber sensors are placed on it upward e Removal of Fiber Sensors Cover Fiber Sensor Pull up Nails after opening covers Next drag fiber sensors 39 5 2 Other Instructions 5 2 1 Vertical Screw Gear Box Shutter Drive Shafts have the correct positions Place them so that the nails are placed toward each other toward inside when assembled Oth
19. e that the safety function works the indicator shows the error number of 10 4 7 2 RICE DITECTION SENSOR The Chest Type Robot has 6 individual Rice Detection Sensors The sensor array on the side of Shutter Blades in the figure below There are 3 safety functions with the fiber sensors One is for Stop status The others are for Operating status They are explained below 1 STOP STATUS The machine does not start if one of sensors detects a material body as safety function The machine does not work even if START STOP Switch is pushed The indicator shows the error number of 10 2 IN OPERATION The machine comes to a halt under Risk Detection Condition Safety Stop The machine is restored by the recovery method as written below The indicator shows the error number of 10 26 a Risk Detection Condition i Rice Detection Sensor 1 Rice Detection Sensor 1 works as a safety sensor Therefore the machine comes to a standstill for safety when the sensor detects a material body ii Rice Detection Sensor 2 6 Normal Detection In a normal case a rice cake is detected from the bottom to top of sensor because rice is coming out through the shutter Therefore detection sensors rice detection sensor 6 5 4 detects a rice cake in sequence for Sushi Mode and 4 3 2 1 detects a rice cake in order for Omusubi Mode The status is in normal detection Abnormal Detection In abnormal cases all other detection cases except for normal
20. erwise the shutter does not operate normally As shown before Vertical Screw Gear Box drives 2 Shutter Drive Shafts and Vertical Screw The engagement mesh of gear part in the gear box should not be changed for correct motion To avoid malfunction mark the points of the gear engagements to reassemble correctly at the time of disassembly 5 2 2 Fiber Sensors Fiber Amp has Light Sending Section and Light Receiving Section Mark Fiber Sensors and Fiber Amps when Fiber Sensors are pulled from Sensor Amps to reassemble them in correct connections CAUTION i Do not make scratches on them and do not dirty them Handle it with care especially take care of the top edges ii Do not contact them to the board and other parts on the board iii Do not bend them unreasonably by force Do not bend them with the angle of more than R25 False bending may cause a lack of light iv Use the special cutter OMURON E 39 F4 in the case that scratches are made on the tops v Check the light amount from the receiving part of Fiber Sensor and if the amount is less than 400 then tune the power of Sensor Amp 40 6 TROUBLE SHOOTING 6 1 Self Diagnosis Function ERROR PRESUMED CAUSE MEASURE ERROR 1 Vertical Screw Motor Alarm Alarm of DC Blushless Motor Driver Confirm and deal with the error referring to Alarm of DC Blushless Motor Driver Wire disconnection Repair the wire disconnection Control Board Fail
21. here are 10 steps of the firmness of sushi rice Softness can be set in only the case that the value is lower than firmness setting For example if the firmness value equals 6 then softness value can be selected from 5 to 1 c About Maintenance Water exposure on the machine is rigorously prohibited because of the existence of electrical circuits in the machine Keep in mind to clean the machine only with a soft wrung cloth a dump cloth Each rotating shaft in the machine has gasket packing on the side of Main Body for avoiding water exposure on or intrusion into the machine Exchange the packing as soon as possible when they are degraded or get aged Water intrusion into Main Body is very dangerous because it may cause breakage of electrical circuits d All Plastic Resin Parts Inside the Machine Clean all the plastic parts with soft sponge Treat them carefully If the plastic part surface has scratches and cracks deterioration it degrades forming capability of rice 10 4 2 SSG SCS Operation Status Transition Figure 1 shows how operation status changes with Rice Detection and START STOP Switch Normal Mode a es ee ee ee ee ee ee ee ee ee ee a ee as Se es ay Initial Filling Detection of Rice Cake Completion of Initial Filling In Initial Operation START switch ON Ec I I i STOP switch ON Power ON gt USG I No Rice fo
22. ic cover is placed for protection on Upper Hopper correctly The cover equips an interlock switch so that the machine will not be in operation without the cover Never remove the interlock switch Operating the machine without the protection cover can result in accidental injury 2 2 Precaution For Servicing Keep the caution written under to avoid injury and or other accidents when the machine is maintained a All the electrical lines are activated when Main Switch is turn on Main Switch is in the side of the projected table on the bottom front of the machine which is the table for sliding the pop up control panel in and out of Main Body Turn off Main Switch and pull out the electric plug from an outlet when the machine is in maintenance Must not maintain the machine until the energized parts discharged to the safe voltage waiting 1 minute after turning off Main Switch and extracting the plug from the outlet Do not touch the charging parts during servicing the maintenance b Check whether water exposure on the electric parts does not exist inside the machine to avoid the electric shocks caused by electric shortage and electrical leakage c Take fully care of handling parts not to injure hands and body parts when assembling the machine because there may have acute edges and or weld flashes on the parts d Reassemble the machine as it were Resume all the status of the parts for example the locations of parts and the electric
23. in the case that the motor is applied with lower voltage less than DC 24V x 0 75 Over Speed Protection Function Number of LED Blinking 6 Times It works when the motor speed goes over 3500 rpm min 42 66 3 Failure Diagnosis Phenomenon Presumed Cause Measure No Power can not be supplied to the machine Power Cable is not plugged in Plug the machine Main Switch is off Turn on Main Switch Abnormal Voltage Apply the correct voltage Circuit Protector in Main Switch is working Find the reason and solve it Failure of Main Switch Exchange Main Switch Failure of SSR Exchange SSR Power Supply Failure Exchange Power Supply Wire Disconnection Repair the wire Failure of Control Board Exchange Control Board Power supplied can not be turned off Failure of Main Switch Exchange Main Switch Failure of SSR Exchange SSR Indication is unusual Impossible to input by key Wire Disconnection Repair the wire Failure of Operation Board Exchange Operation Board Failure of Control Board Exchange Control Board Operation Lamp blinks Instantaneous stop with a rice cake on the shutter Take out the rice cake Softness LED is blinking In Basic Parameter Mode Push Firmness Switch Key Firmness LED is blinking In Common Parameter Mode Push Firmness Switch Key Both LED s
24. is referred for the period from the machine start to the first filling up of rice or for the period from the machine restart to the first filling up of rice after a timeout For other cases Ordinary Timeout Period is referred as the timeout value j Shutter Timeout Period Shutter Sensor judges Shutter as in unusual status if the sensor does not send signals for more than the timeout period even though the shutter is in the right position k Program Version This shows the program version by 3 digits I Production Counter The number of the production is expressed by 9 digits 9 digits are divided into 3 sets of 3digits in counters So each counter has 3 digits respectively Upper 3 digits middle 3 digits and Lower 3 digits express the total production number 21 m Selection of the Way of Operation Mode Change The setting values are 0 or 1 When 0 is selected Motion Mode can be changed by setting only Common Parameter No 11 When 1 is selected Operation Mode can be changed both by using START STOP Switch Softness and Firmness Switch mode changing operation and by setting the common parameter No 11 Refer to Operation Manual to have more detail information The initial value of this setting is 1 4 6 6 Supplementation 4 6 6 1 General Items 1 The relationship between the output pulse and motor rotations 30 pulses is output to the control circuit for one rotation of the motor The number of total p
25. o repair the machine Working on mechanical or electrical components of the system can result in a serious or a fatal accident Keep your hands away from the auger fin section Hopper Screws Horizontal Screw and 2 Hopper Screws inside the hopper of the machine do not insert your hands into there when the machine is in operation Putting your hands into the section may result in accidental injury by being caught up sandwiched and nipped there Keep your hands away from the shutter section of the machine and do not insert your hands into there when the machine is in operation Putting your hands into the section may result in accidental injury by being caught up sandwiched and nipped there Never try to dip the main body of the machine into water and or do not try to pour water over into there for cleaning etc Water exposure may result in fire short circuits electrical leakages and or electrical shocks The hole at the bottom of the machine is not intended for draining any liquid substances but for cleaning the residue out through it Exposing water and or splashing water on over the machine may result in fire short circuits electrical leakages and or electrical shocks and may cause damage and breakage Avoid water exposure on the tool in a case of cleaning around the tool because it has electrical parts inside the bottom section The water exposure may cause a dangerous situation Hold the edge part of the plug and do not hold the
26. of Softness and Firmness ERROR is indicated Refer to Function Self Diagnosis 43 2 Kode Changeover ads Rice Detection Sensor3 Rice Detection Sensor4 Rice Detection Sensor5 Rice Detection Sensor6 Shutter Sensor mast Thermistor ES 1 Q9 Fan E Inner Lid Detection Switch P5 3150 124 Noise Filter Power Plug Circuit Protector crt TBC 5631 01 1110 2 1004 24V 4 5A z Modular J Board g For Program Writing Vertical Screw Mootor M AXHO1SK 10 Horizontal Screw Motor Shutter Motor AXHO1SK 10 Note SUZUMO reserves the right to make such alterations in design as may be considered necessary For this reason illustrations and particulars in this manual may not conform in every detail to models in current production REV 1 SUZUMO MACHINERY CO LTD SUZUMO _ Phone 81 3 3983 1407 Fax 81 3 3993 1756 45
27. quired by monitoring the number of the speed pulses and torque pulses goes over Maximum Current for more than 300 ms It starts again to monitor the driver input current after 1200 msec from the speed reduction and the machine halts if the total current keeps higher than Maximum Current for more than 300 msec judging the machine is in the state of rice stuffing Operation Mode Change The setting value is 0 1 2 for Auto Mode Sushi Mode and Omusubi Mode respectively They can be changed by START STOP Switch Softness and Firmness Switch mode changing operation Refer to Operation Manual to have more detail information Motor Rotation Direction The rotational direction CW CCW is decided by 3 bit signal ON OFF combination Refer to the table below 20 Set Values for Each Motor Rotation Direction Set Value O 1 2 3 4 5 6 7 Vertical Screw CCW CW CCW CW CCW CW CCW CW Horizontal Screw CCW CCW CW CW CCW CCW CW CW Shutter CCW CCW CCW CCW CW CW CW CW g Shutter Open on dly Shutter starts to open delaying by Shutter Open on dly after the machine starts and all rice is discharged h Shutter Close on dly Shutter starts to close delaying by shutter close on dly after the machine detects rice cakes and then screws stop i Timeout Period Sushi There are 2 kinds of timeout period One is Initial Timeout Period and the other is Ordinary Timeout Period Initial Timeout Period
28. r 60 Sec I I I I I I I I I I I I I I I I I I I I I I I I I Temporary Stop Rice cake on Shutter Base No Rice for 10 Sec No rice in the hopper Production of Rice Cakes STOP Status T1OP Switch ON _ Completion of In Operation Completion of Initial Filling Detection of a Rice Gake START Switch ON gt Initial Filling STOP Switch ON Figure 1 OPERATION STATUS TRANSITION 11 z i i i i Possible to set the compression rates only during 4 3 SSG SCS Setting Function and Indication Gr e e SHAH Compression Indication Push AorV Switch with pushing Softness Switch The Softness light is ON Softness Setting Mode Softness Setting Mode se Soft Firm Rice Amount Indication Normal Indication Release Softness Switch lt lt D Decrease BEEN ug Push AorV Switch with pushing Firmness Switch The location of the lighting moves The Number of lightings is determined de The Firmness light with pushing AorV Switch is ON Firmness Setting Mode Firmness Setting Mode Release Firmness Switch UU UU UUM UU Soft Fim RICE AMOUNT SETTING Pushing AV Switch enable to change the rice amount setting up to 10 steps The location of the ae moves COMPRESSION SETTING The machine has 2 modes for the compression One is Softness Mode and the other is
29. r Lid Detection Sensor Exchange Inner Lid Detection Sensor Wire Disconnection Repair the wire disconnection Failure of Control Board Exchange the control board 41 6 2 Blushless Motor Driver Alarm p LED Figure 7 Schematic Diagram of Blushless Motor Driver AXHD15K It is possible to confirm the kind of protection function works by watching the number of the LED blinking in the beginning Just after the protection starts to work LED blinks the prescribed number times as shown below with 0 3 sec lighting and 0 3 sec interval After that it iterates blinking with the time interval of 1 5 sec and the lighting interval of 0 3 sec 1 oo Overload Protection Function Number of LED Blinking 2 Times It works when the torque over the motor rated torque is burdened to the motor for more than 5 sec or a motor operation an instantaneous stop or a rotational direction changeover are iterated Phase Absence Protection Function Number of LED Blinking 3 Times It protects malfunctions of motor in driving in the case of a sensor wire disconnection of the motor in the wire set Overvoltage Protection Function Number of LED Blinking 4 Times It works when the load is lowered the inertia goes over the allowed load inertia value or DC voltage applied to the motor goes over the voltage of DC 24V x 1 15 Low Voltage Protection Function Number of LED Blinking 5 Times It works
30. ration All mechanical or electrical adjustments or repairs of the machine must be conducted by or under the supervision of qualified persons who have been trained for the product Failure to follow directions and proper safety procedures bellow when working on mechanical or electrical components of the system can result in a serious or fatal accident The degrees of the hazardous situations are mainly grouped into 3 types in the case of mishandling and improper use ignoring the instructions hereunder Please observe those instructions This symbol preceding any specific instruction indicates that the failure to observe the instruction will cause serious or fatal injury to the personnel and loss of life immediately This symbol preceding any specific instruction indicates that the failure to observe the instruction could cause serious or fatal injury to the personnel and loss of life immediately This symbol preceding any specific instruction indicates that the failure to observe the instruction may cause serious or fatal injury or damage to the equipment The picture symbol as figured preceding any specific instruction indicates the prohibition of handling and or operation The picture symbol as figured preceding any specific instruction indicates the way of handling and or operation Personnel engaged in the machine must follow the instruction Only qualified persons who have received the training for the product are allowed t
31. uction Speed Refer to Operational Manual 14 4 6 2 COMMON PARAMETERS They are common set values for each Operation Patterns above 4 6 3 HOW TO CHANGE INTO PRAMETER SETTING MODES The parameter setting mode is selected by inputting the password when the machine is in stop status The stop state is defined as the status that Main Switch on Control Panel on the projected table on the bottom front of the machine is turned on pushed and the machine is stopped with START STOP button switch The password is input by pushing Vand Abuttons quickly sequentially as A V A V A V A V for Basic Parameter Mode and quickly sequentially as A A A V A V V V for Common Parameter Mode Figure 2 explains how Parameters Mode can be set and be resumed to the original mode In Basic Parameter Mode LED on Softness Switch blinks Input the password Push Firmness Switch Parameter Number Indication Push Softness Switch Setting Value Indication i NE Push V or A Switch Release Softness Switch RR Parameter Number Change Setting Value Change Figure 2 Parameter Mode Transition 4 6 4 How to Operate and Indicate Parameter Mode 4 6 4 1 Indication In Parameter Mode Indicator Bars in Indicator are lit so that it informs the operator the number for the selected parameter The number is defined by adding the digit numbers expressed in binary number system as Figure 3 For example the number expressed in Indicator is calculated by adding 2
32. ulses is used to count the number of the rotations 2 Motor speed is expressed by Motor rotation speed r min the set value of Speed 250 3000 Parameter Adjustment Direction 1 Adjustment when shutter does not close completely Increase Basic Parameter 5 Shutter Close Position 2 Adjustment when rice amount does not change apparently with changing the set value Increase Basic Parameter 7 Rice Amount on dly 3 Adjustment when rice firmness is softer even if the set value compression of 1 to 10 is changed within full range Increase Basic Parameter 8 Basic Compression 4 Adjustment when rice firmness does not become firmer even if the set value compression is set higher Increase Basic Parameter 9 Compression Motion 22 5 Adjustment when rice firmness does not become firmer even if the set value compression is set higher Increase Basic Parameter 8 Basic Compression 6 Changing the timeout period Change the set values of Common Parameters 15 16 17 18 7 In case of checking the number of the production Investigate the numbers of common parameters 21 22 23 23 4 6 6 3 Initial Values of Parameters Table3 Standard Data for All Motion Modes Data Name Initial Value Rice Amount Compression Rate Softness Compression Rate Firmness Compression Rate The above written data can be set with the button switches in control panel Refer to Operation Manual for more detail explanation
33. ure Exchange the control board ERROR 2 Horizontal Screw Motor Alarm Alarm of DC Blushless Motor Driver Confirm and deal with the error referring to Alarm of DC Blushless Motor Driver Wire disconnection Repair the wire disconnection Control Board Failure Exchange the control board ERROR 3 Shutter Motor Alarm Alarm of DC Blushless Motor Driver Confirm and deal with the error referring to Alarm of DC Blushless Motor Driver Wire disconnection Repair the wire disconnection Control Board Failure Exchange the control board ERROR 6 Failure of Thermistor Exchange the thermistor FAN Thermistor Wire disconnection Repair the wire disconnection Abnormality Control Board Failure Exchange the control board ERROR 7 Breakdown of Shutter Exchange the shutter sensor Shutter Sensor Sensor Abnormality Wire disconnection Repair the wire disconnection Control Board Failure Exchange the control board ERROR 8 Rice Filling Up Take all rice away that puts a heavy Rice Filling Up load on motors ERROR 9 No Rice Supply rice Timeout Error 10 Safety Function works Eliminate the abnormal cause s Safety Sensor by Rice Detection Sensor Safety Function works by Inner Lid Detection Sensor Set Inner Lid in the right position and in the correct manner Failure of Rice Detection Sensor Exchange Rice Detection Sensor Failure of Inne
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