OPERATION MANUAL

www.idm.com.tr

MEKATRONİK

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CONTENTS

General Instructions 4

Safety First 5

1- Installation 6

1.1 Handling the Robot 6

1.2 Placing the Doner Robot 6

1.3 Precautions During and After Installation 7

1.4 Gas Connection 12

1.5 Instructions to Convert to Different Gases 17

1.4.1 Gas Reduction Calibration 12

1.4.2 Location of LPG Cylinder 13

1.4.3 Parts to be Replaced During Device’s Lifetime 14

1.5.1 Points to Take into Consideration 17

1.5.2 Gas Connection 17

1.5.3 Natural Gas Connection 17

1.5.4 Liquid Gas Connection 18

1.5.5 Changing Gas Type 19

1.5.6 After Conversion 21

1.5.7 Sealing and function check 21

1.5.8 Proper Burning Status 22

1.4.3.1 Gas Nozzle 14

1.4.3.2 Radiants 15

1.4.3.3 Gas Valves 15

1.4.3.4 Radiant Wires 16

1.4.3.5 Cylinder and Surrounding Parts 16

1.5.7.1 In case of Gas Leak 21

1.5.5.2 Checking Gas Connection 21

1.5.8.1 Technical Specifications - Gas 22

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2- First Operation and Preparation 23

8- Mounting Replaceable Parts 40

9- Potential Problems 43

10- Spare Parts List 45

11- Mounting Pictures 46

12- Electrical Diagrams 49

13- Certificates 53

14- Points to Take into Consideration by Customers in terms of Warranty 54

15- Technical Service 55

3- Cooking and Cutting 29

5- Cleaning and Maintenance 34

6- Points to Take into Consideration 36

4- Operation Functions 31

7- Mounting Parts Supplied Not Attached to Device 39

2.1 Plugging and Starting the Robot 23

2.2 Sharpening 24

2.3 Arm Pressure Setting 27

2.4 Placing Doner 28

3.1 Lighting the Grill 29

3.2 Cooking 29

3.3 Cutting 30

5.1 Robot Cleaning 34

5.2 Grill Cleaning 34

5.3 General Maintenance Instructions 35

6.1 Types - Shapes of Doner that can be cut using the robot 36

6.2 Doner Types - Shapes that cannot be cut using the robot 37

6.3 Points to Take into Consideration when Using the Grill 38

4.1 Remote Control Key Functions 31

4.2 Touch Screen Functions 32

7.1 Hood 39

7.2 Bain-marie 39

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General Instructions

1. Always follow all instructions stated on the robot or in documents delivered with the robot.

2. Contact authorized service in case of any faults. Do not intervene until service arrives.

3. Robot must be installed by the authorized service.

4. Usage errors can occur when the robot operator is sleepless, exhausted or under the effect of substances such as medicine or alcohol. Robot must not be used in these situations.

5. Usage errors can occur when the robot operator is sleepless, exhausted or under the effect of substances such as medicine or alcohol. Robot must not be used in these situations.

6. Always plug the robot to a grounded socket and unplug if you are not going to use it for a long time. Keep the power cable away from heat, grease, objects with sharp edges and mov-ing parts of the device.

7. Protect the robot from external effects such as excessive heat, humidity, direct sunlight, dust, rain, snow.

8. Do not use any accessories not specified by the manufacturer.

9. Carry out all operations such as switching the grill unit on-off, gas or electrical connections carefully by reading the operation manual. Gas or electrical connections must be carried out by authorized people.

10. This robot is only designed to cut doner. Do not try to cut anything else besides doner.

11. Ready-made doner is recommended, but fresh-prepared doner as well can be cut by this robot. Freshly prepared doner must be trimmed according to the sizes that doner robot can cut.

12. This device is for professional use and it must only be used by qualified people.

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Safety First1. The robot should first be started by a member of staff who has read the operation manual or had training. When the user is near the robot and someone else has the remote control, accidental use of keys of remote control can cause injuries. This is a risk that should be con-sidered. 2. Always follow safety signs on the robot. You must stand at least 1 m away when robot is running or when the controller is used to run. Moving parts of the robot can cause accidents such as impact and crushing. 3. Never carry the robot controller in your pocket. Controller keys can be unintentionally pressed in the pocket and start the robot. 4. Follow Sharpening instructions during sharpening. Otherwise, highly sharp knife can cause injuries.

5. Do not try to serve while cutting the doner with robot. Cutting arm can cause injuries. Wait until cutting is finished before serving and put receiving buttons depending on the robot model before serving.

6. Be careful to prevent doner from falling while placing doner. First, switch the motor rotat-ing the doner off, place bottom part of doner to the rotating motor rest and insert safety knob on doner shaft.

7. Make sure the hood is on before supplying gas to grill. Turn off gas connection if hood stops for any reason or it breaks down.

8. Appliance must be installed in accordance with the current rules and used in sufficiently ventilated spaces. Air circulation must be suitable for combustible and explosive gases that can accumulate in the room to discharge (gas accumulation in gas cylinder part and around connections). Air circulation also provides the ideal air conditions required for the grill to work. Grill consumes the oxygen in fresh air and this causes air quality in the room to reduce. For this reason, pay utmost attention to the air circulation in the room.

9. Always follow instructions for installing and operating the appliance.

10. Packaging material resulting from unpacking the appliance must be disposed in accord-ance with regulations.

11. Do not store harmful substances in the room where appliance is installed.

12. Machine securing can be carried out depending on the decision of technical service for industrial machines.

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1 INSTALLATION

1.2 Placing the Robot

1.1 Handling the Robot

1.2.1 Make sure the place where doner robot will be operated is set before starting installa-tion. If you have an original stand, hood height must be preset. (Contact the manufacturer for the original stand) Dimensions of the stand where robot must be operated are given in Figure 1-1, Figure 1-2, Figure 1-3, Figure 1-4 and Figure 1-5.

1.2.2 Stand of the robot must be stainless steel and designed not to vibrate during opera-tion.

1.2.3 After robot is placed, power cable must be plugged to a grounded socket.

1.2.4 Electricity line connected to the robot varies depending on the model and country, but it must be connected to mains through a 25 A fuse.

1.2.5 Robot must be secured to the counter it is installed if technical service considers neces-sary.

Robot is tightly sealed in the factory. It must be transported in its own packaging to its final installation location. Unscrew the screws using screwdrivers or hex bits ends while unpack-ing. During manual handling after unpacking, carry by holding the emergency stop button and cutting arm and do not hit the emergency stop button and cutting arm anywhere. Never hit the edge of the robot to wall or door while passing through doors or narrow spaces. It must be lifted and placed on the stand using sufficient manpower. Be careful to prevent injuries during carrying and always wear gloves.

Information: If 250kg or 350kg robot is to be installed, it must be secured to the stand using safety parts. Height of hood over doner robot from the stand must be at least 20 cm more than the height values stated in “Table 1”. Ventilation requirement is also stated in “Table 1”. Please follow these data during installation. Never reduce hood intake to save on heat. Never place appliances emitting heat such as fryer, toaster, etc. near the electrical board of doner robot.

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1.3 Precautions During and After Installation

1.3.1 Distance between machines must be at least 60cm.

1.3.2 Distance from the machine to the wall at the back must be at least 50 cm.

1.3.3 Distance from the machine to the side wall must be at least 50 cm.

1.3.4 Upper hood distance must be 15 - 20 cm. above the top of the machine.

1.3.5 Do not get approach to the machine closer than 30 cm. when running.

Figure 1

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Figure 1: Robot - Stand Dimensions

100 KG

130 KG

Figure 2-1

Figure 2-2

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150 KG

250 KG

Figure 2-3

Figure 2-4

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ROBOTMax.

Capacity LPG - LNG WIDTH LENGTH HEIGHT VENTILATION REQUIREMENT

GRILL POWER

100 KG 4 Radiants 85 cm 105 cm 111 cm 32 m3 10 kW

130 KG 5 Radiants 85 cm 105 cm 123 cm 40 m3 12,5 kW

150 KG 5 and 10 Radiants 99 cm 116 cm 132 cm 40 - 80 m3 12,5 - 25 kW

250 KG 7 and 14 Radiants 99 cm 116 cm 178 cm 56 - 112 m3 17,5 - 35 kW

350 KG 14 and 16 Radiants 106 cm 111 cm 180 cm 112 - 128 m3 35 - 40 kW

MODEL R01 R02 R03 R04 R05

Total Consumption (V) G20 , m3/h 0,27 0,54 0,81 1,10 1,35

Total Consumption (M) G30 , kg/h 0,16 0,32 0,48 0,64 0,81

MODEL R06 R07 2R05 2R07

Total Consumption (V) G20 , m3/h 1,62 1,89 2,70 3,70

Total Consumption (M) G30 , kg/h 0,96 1,12 1,60 2,24

Table 1

350 KGFigure 2-5

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1.3.6 Placing Robot on Balance

Figure 3

Apply water gauge as shown in Figure 2 after placing the robot where it will be used. You can make required corrections using adjustable robot feet.

ROBOTMax.

CapacityELECTRICAL WIDTH LENGTH HEIGHT GRILL

POWER

100 KG 6 Resistors 85 cm 105 cm 111 cm 9 kW

130 KG 7 Resistors 85 cm 105 cm 123 cm 10,5 kW

150 KG 7 Resistors 99 cm 116 cm 132 cm 10,5 kW

250 KG 10 Resistors 99 cm 116 cm 178 cm 15 kW

Table 2

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1.4 Gas Connection

Remove the protection covers on connections as shown with yellow in the figure before con-necting the gas. Always use Teflon tape when connecting gas pipes. Check for the leakage using gas leakage spray after the connection is finished. (never use lighter or flame to check)- Adjustment must be made with max. 20 mbar regulator for LNG and max. 30 mbar regula-tor for LPG. (see Table 1 gas table.)

1.4.1 Gas Reduction Calibration1.3.1.1 Light the radiant to be adjusted.

1.3.1.2 Remove gas adjustment knob and use a flat-end screwdriver to move 2 turns anticlockwise as shown in the figure.

Figure 4 Figure 5

Warning: Radiant stones’ lifetime will be shortened if substances such as alcohol, oil, etc. are used to light radiants. Gas pressure values vary depending on country. Check the gas pressure values for your country from the label on the grill and set the regula-tor to this value.

Warning: Contact technical service if the appliance is to be converted for use with other gases.

Warning: All gas connection operations must be carried out by technical service.

Figure 6

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1.4.1.3 Replace gas adjustment knob and set it to low level. You will observe that radiant is not decreased in this state.

1.4.1.4 After removing gas knob again, use a screwdriver to set the radiant clockwise to desired low level while observing the running radiant.

Thus, complete the calibration. You can set the desired level for each radiant repeating the above procedure.

1.3.2.1 For models with LPG, place cylinders at least 50 cm away from the appliance as shown in the figure. Make sure gas pipe is not bent or crushed.

1.3.2.2 Use of 12kg standard cylinder is recommended. 12 kg standard cylinder has a diam-eter of 360mm and a height of 450 mm. (Incl. regulator)

1.4.2 Location of LPG Cylinder

Gas Pressure Settings

II 2ELL3B/P 20,50 mbar DE II 2E20 mbar LU,PL

II 2H3B/P 20,50 mbar AT,CH I 3P37mbar PL

II 2H3B/P 17-20,50 mbar CZ II 2L3B/P 25,30 mbar LU,PL

I 3B/P 30 mbar CY,HU,IS,MT,NO II 2H3+ 25,28-30/37 mbar CH,ES,GB,GR,IE,PT

II 2E+3+ 20/25,28/37 mbar BE,FR II 2H2B/P 20,30 mbar DK,EE,FI,LT,RO,SE,SI,SK,BG,TR

Table 3

Figure 7

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1.4.3 Parts To Be Replaced During Appliance Lifetime

1.4.3.1 Gas Nozzle

- Gas nozzle

- Radiants

- Gas valves

- Radiant wires

- Cylinder hood

- Holding valve

- Pipe clamp

- Flexible pipe

WARNING: Parts listed on the side must not be adjusted or replaced by users. Please contact our company for parts supply and replacement.

Figure 8

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- Use a long-end lighter to light the radiant from a distance protecting yourself from the first ignition.

- Valves must be replaced by the authorized service at least once in 2 years.

1.4.3.2 Radiants

1.4.3.3 Gaz Muslukları

Figure 9

Figure 10

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For machines working 24 hours, doner grill wires are recommended to be replaced by the authorized service at least once a year.

1.4.3.4 Radiant wires

1.4.3.5 Cylinders and Surrounding Parts

- Pipe must be maximum 1.5 meter-long.- This is valid only for appliances running on LPG.- Safety gas hose or plastic hose and holding valve must be installed (at least 1/2” input). Hose must have a diameter of 8 or 10 mm.

- It is recommended to replace the pipe used with the cylinder at least every 3 years and the hood at least every 2 years. - Install a holding valve on the pipe between cylinder and appliance. Replace this every 2 years.

- Periodically check if the gas supply pipe is compliant with national rules in force and replace if necessary.

Figure 11

Figure 11

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1.5.1 Points to Take into Consideration

1.5.2 Gas Connection

1.5.3 Natural Gas (NG) Connection

WARNING: Your appliance must only be converted to other gas types by authorized people according to instructions stated in this document.

WARNING: Wrong connection or setting can damage your appliance. Appliance manu-facturer will not be responsible for wrong connection or setting.

Check symbols found on identification plate on the appliance carefully. If your country’s sym-bol is not found here, follow technical instructions in your country for necessary settings.

Be informed about the gas type and pressure in the local distribution network before install-ing the appliance. Make sure all settings are correct before using the appliance.

Follow local and national directives (regulations).

Allowed connections: These instructions are valid for countries stated on identification plate on the appliance.

If the appliance is installed, connected and used in a country that is not stated on the id plate, follow an installation and mounting instruction containing required information to ensure connection conditions for the appliance in the related country.

If natural gas (NG) is to be used, gas is connected via a gas hose or a safety gas hose with screw threaded connection on each end.

1.5 Instructions to Convert to Different Gases

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1.5.4 Liquid Gas (LPG) Connection

Caution!

Follow regulation specific for the country.

If liquid gas is to be used, gas is connected via a gas hose or a fixed connection.

Points to take into consideration while using a gas hose:

- Use safety gas hose or plastic hose (with a diameter of 8 or 10 mm).- It must be secured to gas connection using a certified connection equipment (e.g. hose clamp).- Hose must be short and tightly sealed. Hose must be max. 1.5 m-long. Follow current regu-lations.- Gas hose must be replaced once a year.

1.5.4.1 Place the new gasket inside the connection part. Make sure the gasket is securely fitted in its place.

1.5.4.2 Install connection part (secured using a 24” wrench) on appliance gas connection input (using a 22” wrench).

Figure 12

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1.5.5 Changing Gas Type

1.5.4.3 Install safety gas hose and tighten using screw connection or clamps.

1.5.4.4 Refer to “Sealing Check” section to check sealing. Open the closing device of gas con-nection.

Information: Use a torque wrench while connecting the appliance.

To Change Gas Type

- Change gas connection part. - Change injectors of burners.- Change bypass injectors on burner valves depending on factory gas setting of the appli-ance and tighten them securely.

Figure 13

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WARNING! After conversion, the technical service carrying out the conversion will replace the label on the robot that shows gas type according to the new gas type.

- To convert your appliance to LNG (natural gas), the bush on steel cord hose end and suit-able (LNG) radiant gas nozzle must be replaced by authorized service.

-Authorized staff will carry out the required cleaning, labeling and gas pressure measure-ments using a manometer and deliver the appliance to user after conducting the test of grill that has run for half an hour to an hour.

- Different nozzles must be installed for LPG and LNG grills.

- G30 - Cylinder (LPG) must have a 30 milibar pressure. G20- Natural gas (LNG) must have a 20 milibar pressure.

Figure 15

Figure 14

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1.5.6 After Conversion

- After converting the gas type, check for sealing. See “Sealing Check” section for this.- Check burning status after changing gas type. See “Proper burning status” section for this.- Note the new gas type and pressure on the table. See “Points to Take into Consideration” section.

Caution!It is MANDATORY to attach the sticker in the bag that contains the gas type and has a star symbol on to predefined space on type plate of the appliance after changing gas type.

1.5.7 Sealing and function check

Danger of explosion!

1.5.7.1 In case of Gas Leak

1.5.7.2 Checking Gas Connection

Be sure not to cause sparks. Do not use flame or open fire. Check sealing only using a suitable foam.

- Close closing equipment.- Ventilate the related space sufficiently.- Check gas and injector connections once again.- Repeat sealing check.- Sealing must be checked by two people as mentioned below.

1. Open the closing device of gas connection.2. Apply suitable foam around gas connection.

If bubbles or diffusion is observed on foam surface indicating a gas leak, follow procedures stated in “In case of gas leak” section.

Follow the same procedures for the part closed with a nose plug.

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1.5.8 Proper Burning Status

1.5.8.2 Technical Specifications - Gas

1.5.8.1 Burners

Check each burner for burning status and soot formation after changing gas type.

Compare injector values with values in the table in case of a problem.

* For France and Belgium

*G20/G25 G20 G20 G25 G25

Gas Pressure (mbar) 20 / 25 25 20 1,10 25

Injector (mm) 1,2 1,2 1,2 1,2 1,2

G30/G31 **G30 G25.1 G27 G30

Gas Pressure (mbar) 28-30 / 37 50 25 20 37

Injector (mm) 0,80 0,80 0,80 0,80 0,80

Table 4

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2 START-UP AND PREPARATION

2.1 Plugging and Starting the Robot

2.1.1 Move pacco switch shown in Figure 3 to “1” position after plugging in.

2.1.2 When on/off switch on the box shown in Figure 16 is set to “1” position, the fan in the electrical box will be activated. Move emergency stop button in the direction of arrow shown in Figure 17 to start the robot. Robot will not run if this button (4)is pressed. Buttons no. 3 and 4 must be on for the robot to start working.

Figure 17 : Emergency stop button for doner robot

Figure 18: Infrared receiver on/off button

Figure 16

2.1.3 Button no. 5 must be moved to position 1 shown in Figure 18 (for single button models) in order to be able to use the controller after the robot is started. If your robot has a display, the receiver button on the display must be activated.

Warning: Emergency Stop must only be used in emergencies. Switch the robot on/off using 0-1 position of pacco switch.

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2.2 Sharpening

2.1.4 Set Remote Control Button on front panel to “on” position in order to start the machine using controller in models without display. Point the remote control to the front panel and press “Start/Stop” button once and observe if machine arm is moving. This operation resets the appliance. You can carry out this operation on the display in models with display. By pressing the “START” button on the screen that appears after the “MAIN MENU” is clicked, you can perform the starting task with the controller. If you want to use the controller in the model with display, click “MAIN MENU” button and “CONTROLLER” button in the next screen to activate the controller. You can continue operations using the controller. You can find the detailed description about display menus in the operation section.

2.1.5 Place grill covers using two small screws. If you are using the controller arm for this op-eration, make sure the “Remote Control” button is off. If it is a model with display, turn off the remote control feature. This is important for your safety. If robot is started with the remote control when you are using the grill, cutting arm may hit and cause injuries.

2.1.6 If the grill is moved, it is withdrawn to the farthest back position and the triangle tray is placed.

2.1.7 After the tray is placed, fill the boiler with water. Fill 1 to 1,5 liters of water after making sure that the water discharge valve is closed. Turn the boiler temperature knob to 100 from 0.

2.1.8 Place the front tray of boiler inside. Align the back tray so that it flows oil to front tray.

2.2.1 In order to sharpen the blade, press the sharpening button on the controller to move the arm down and position the arm for sharpening.

Figure 19

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2.2.2 Install the two circular nuts on the screw behind the cutting head.

2.2.3 Place the 140 mm-cutting blade in its place with the side written side facing front. Then, install the blade screw.

Figure 20

Figure 21

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2.2.4 Tip of the cutting head cover can be used as a screwdriver. Install and tighten the crown and two special screws of the cutting head with the front cover.

Warning: Blade screw has reverse threads. When you face towards the blade, the screw will loosen if you turn clockwise.

2.2.5 Thickness of the doner cut is mechanically adjusted with the movement of circular nuts. This adjustment is performed by changing the distance between cutting blade bottom support and the blade.

Figure 22

Figure 23

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2.2.6 Rotate the blade by pressing the sharpening button on the controller when the cut-ting arm is in sharpening position and the blade is installed. Set the cutting thickness to widest position to use sharpening accessory comfortably. Contact sharpening accessory on the inner surface of the blade with a 15-degrees angle. Sharpen the blade moving forward and backward. Continue this operation without changing the angle until you observe blade shavings rotating on the front surface. Then, fix the front side of the blade by contacting the sharpening accessory on the rotating surface with a 2-degrees angle. Set the mechanic thickness to previous position after sharpening. Nuts must be tightened alternatively and must not move during cutting.

Warning: Remote control must be off during blade sharpening.

2.3.1 Set the optical pressure setting button to the finest position by turning anti-clockwise. Then lift the cutting arm. You can observe the pressure setting thickness from the position on the yellow label.

2.3 Arm Pressure Setting

Figure 24 Figure 25

Figure 26

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2.4 Placing Doner

2.4.1 Insert doner shaft to doner taken out of the freezer. Place the doner installed on the shaft on the hub first by preventing the sliding of the bottom and the insert other end to the doner fixing part. Finally, place the bottom part uniformly. If multiple trays are to be fit, small-est tray must be at the bottom and largest must be on the top.

Figure 27

Figure 28

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3.1.1 Light the doner grill starting from the top radiant. Others will be lit automatically as the gas is increased.

3.2.1 Rotate doner by pressing the cooking button on the controller. Apply pre-cooking on low heat for 20 to 30 minutes. Starting to cut prematurely may cause defects in doner. Cook-ing function is detailed in “Using the Display” section.

3 COOKING AND CUTTING3.1 Lighting the Grill

3.2 Cooking

Figure 29

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3.3.2 After pre-cooking, press the cutting button on controller to start cutting doner. You can carry out this operation on the display in models with a display.

3.3.3 You can set the optical pressure setting that is set to finest to get a continuous cutting surface, i.e. until you get a cut with the desired thickness by manually turning it clockwise and increasing the pressure. Mechanical cutting thickness setting can be changed using circular nuts behind the cutting head provided that optical pressure level is fixed and desired measurement is achieved.

3.3 Cutting

3.3.1 Doner robot can cut frozen ready-made doner and freshly wrapped and trimmed doner. If fresh-prepared doner is to be placed, pins that are supplied with the robot must be used. You can ask for our company’s support for accessories that doner is to be wrapped in if required. Fresh doner must be tight and solid. It must be solid to not to lose shape during cutting and cooking.

Figure 30

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4 OPERATION FUNCTIONS

4.1.1 START/STOP: Used to initiate or to reset the robot. Used to stop any operation.

4.1.2 SHARPEN: Robot must be reset in order to be active at the initial start. Used for sharpening. Cutting arm moves to sharpening position when pressed once and cutting blade starts rotating for sharpening when pressed for the second time. The “beep” sound is the warning sound indicating sharpening.

4.1.3 CUT - NONSTOP: Robot must be reset in order to be active at the initial start. It is used for cutting when doner is cooked. When the button is pressed, robot will carry out a detection on the doner. Cutting will start after this detection process. In order to activate nonstop cutting, press this button for the second time when cut-ting blade is cutting. Automatic cutting is activated with a signal sound and it continues nonstop following a turn of cutting. 4.1.4 RIGHT 1+1: Robot must be reset in order to be active at the initial start. It is used to rotate doner right. Rotating speed is 3rpm. Rotating will stop when pressed again while turning right. When it is pressed during cutting, it switches to automatic cutting program with the signal sound. After one cutting and one cooking cycle, the robot continues cutting at the end of the operation using the same program automatically. 1+1 automatic cycle will continue unless a button is pressed.

Figure 31: Kızıl ötesi uzaktan kumanda

4.1.5 COOK 2+1: It is pressed to perform cooking. Robot must be reset at the start for this to be active. It stops rotating when pressed again in the cooking mode. Rotating speed while cooking is 1rpm. Doner will stop if pressed again while cooking. If this button is pressed again during cutting (2+1), then automatic program is set. After one cutting and one cook-ing cycle, the robot continues cutting at the end of the operation using the same program. Automatic program will be deactivated if any button is pressed.

4.1.6 LEFT 3+1: Robot must be reset to be active at initial start. Used to rotate doner left. Rotating speed is 3rpm. Rotating will stop if pressed again while rotating left. When it is pressed during cutting, it switches to automatic cutting program with the signal sound. After one cutting and 3 cooking cycles, the robot continues cutting at the end of the operation using the same program automatically. 3+1 automatic cycle will continue unless a button is pressed.

4.1 Remote Control Key Functions

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4.2 Touch Screen Functions4.2.1 You can select the language in the intro screen and move to “MAIN MENU”. If no selec-tion is made, it is preset to Turkish.

4.2.2 START: Start button will be set to stand-ard settings when the robot is first started. You cannot use other functions before doing this. If you press start button during cutting, cutting will be cancelled and doner sizes in memory will be reset.

4.2.3 COOK: When the cook button is first pressed, doner will start rotating and cooking the meat. If you press the cook button again during this operation, operation will stop and cooking will end.

4.2.4 In order to set robot to 3+1 mode, press cook button while the cutting arm is decreasing.

4.2.5 CUT: When you press cut button after cooking, cutting will be initiated. Cutting will stop and it will switch to standby mode if you press the cut button again when the cutting arm is moving up. In this mode, cooking will continue until you activate again. Press cut button again to resume cutting.

4.2.6 In order to switch robot to 1+1 or Nonstop cutting mode, press cut button while cutting arm is lowered.

4.2.7 CONTROLLER: Use this button to turn the controller on/off.

4.2.8 ROTATE: Rotates doner in arrow direction.

4.2.9 SHARPEN: When this button is pressed, “Are you sure you want to sharpen?” question is asked. If you answer yes, cutting arm will be lowered and blade will be ready for sharpening.

Figure 32

Figure 33

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4.2.14 Automatic Grill Tracking

4.2.10 GRILL MONITORING:

4.2.11 FORWARD: Grill will move forward as long as you press this button.

4.2.12 BACKWARD: Grill will move backward as long as you press this button.

4.2.13 TRAY 50 - TRAY 35: When the robot is first started and 50- and 35- trays are in place, the distance between grill and 50- tray is equal to the value given in the “Grill DISTANCE” sections as seen on the screen. As doner will get smaller as it is cooked and cut, 50- tray is removed and doner will be on 35-tray. You need to set grill distance again in this case. Press “TRAY50” button on this screen after removing 50-tray in order to perform this operation. The button will turn green and the distance will be automatically added to “Grill DISTANCE” sec-tion. If required, it can be moved to doner as much as the current distance using the forward button. Same procedures are followed when 35- tray is removed.

When grill monitoring button is pressed, following screen appears. Press “RESET GRILL” button when robot is first started. This must be performed if robot is turned off and on again. After this, red button on the left bottom of the screen turns green and it is ready.

As the name suggests, it allows grill to automatically track the doner. First, “TRACKING DISTANCE” must be set for automatic tracking. This distance must be equal to the doner thickness cut by the robot. After selecting tracking distance, you can start the operation by pressing the automatic grill tracking button. If doner is cut 2mm in each turn, grill will get 2 mm closer to doner at the end of that turn. This will be automatically sustained until the grill distance is “0”. When you need to remove the 50- tray in this case, you can remove the tray following the steps above. Grill distance is set again with this procedure.

You can carry out this when you first start cutting doner or during the ongoing op-eration. You need to follow the operation sequence mentioned above. When automatic cutting is initiated, round symbol will turn green and “FORWARD-BACKWARD” buttons will disappear on the screen. You just need to press this button again to exit automatic tracking mode.

Figure 34

Figure 35

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5 Cleaning and Maintenance

5.1.1 All trays and cutting equipment of the robot contacting doner can be removed and washed. Make sure these equipment are not deformed during and after washing.

5.1.2 Cutting blade can also be removed and washed. Cutting head housing must be wiped using a hygienic damp cloth. Never apply water using a hose on any part of the robot. Other-wise, rotating systems, especially the electrical box will be damaged. All other dirty parts of the robot must be wiped using a damp hot cloth.

5.1 Robot Cleaning

5.2 Grill Cleaning5.2.1 Doner grill must not be cleaned by washing with a hose and no oil-removing chemicals must be sprayed into radiants. Grill covers can be removed and washed. Apply oil-removing spray on dirty surfaces of doner surface and wait for 15 minutes. Use a wire wool or scouring pad to scrub.

5.2.2 A thin oil layer will be formed on the grill after a time. This layer must be cleaned regularly. Otherwise, accumulated oil can be inflamed and poses risks for the user. Clean the covers at the back of the grill as you remove them by lifting up and pulling towards yourself.

Table 5 -Doner Types - Shapes that can be cut using the robot

KG DIAMETER HEIGHT

100 KG 45 cm 70 cm

130 KG 45 cm 80 cm

150 KG 52 cm 80 cm

250 KG 52 cm 120 cm

350 KG 62 cm 120 cm

Figure 36

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5.3 General Maintenance Instructions- Disconnect electricity and gas from the appliance before cleaning.

- Never carry out maintenance when the appliance is powered.

- The appliance requires periodical maintenance after 3000 hours of use or once a year.

- Wipe the appliance using a cloth damp with warm and soapy water before it cools.

- Do not use cleaning substances and tools that may cause scratches on the appliance. (Use chemical cleaners if required)

- Never clean the appliance using pressurized water or steam pressure.

- Do not let water enter through ventilation holes of the appliance during cleaning.

- While cleaning the pin hub, do not let any water etc. enter the motor.

- Clean the oil tray every day for hygiene.

- If you observe a dangerous condition on the appliance, contact the authorized service. Do not let people without qualification to tamper with the appliance.

Oil is accumulated in certain parts of the appliance during daily operation. These parts (front and top parts of the grill, grill shields, doner shaft, doner tray that doner is placed on, back tray that doner pieces fall and front tray-boiler where oil flows to) must be cleaned every day. It may cause fire as it will catch fire when not cleaned. Therefore, pay attention to daily cleaning.

- Always follow operation and maintenance instructions.

- This device is for professional use and it must only be used by qualified people. The ap-pliance must not be used by people lacking the required knowledge about how to use the appliance.

- Authorized technical service must be contacted for installation and gas conversion (LPG-LNG conversion) of the appliance. These operations must be carried out by trained and experienced personnel.

- Do not store any flammable objects closer than 50 cm on the front and 30 cm from the sides while using the appliance.

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6 Points to Take into Consideration

6.1.1 Doner robot can be used to cut many different types of meat such as mince, chicken, turkey, sausage, or fish. Important point here is that doner must have a certain size and shape. Also, doner must not be deformed during cutting. Deformation is mostly common with meat such as mince or soy mince doner. Doner with deformed surface is detected by robot as one of the faulty shapes. Therefore, cutting will not start or it will stop due to error even if it starts.

Figure 37: When a large diameter doner is placed, always use the additional 35 cm or 25 cm -diameter bottom trays.

6.1 Doner Types - Shapes that can be cut using the robot

6.1.2 Maximum doner dimensions that can be placed on robot are given in Table 4. Dimen-sions of doner to be placed must not exceed the values in the table. Inclined doner surface is precisely traced by the cutting blade and is cut. The only potential problem here is placing a doner with an inclination more than 8 degrees. In this case, cutting will start on the top part of doner but lower parts will not be cut as inclination is too much. In order to prevent this, make sure the doner to be placed on the robot to have a slight inclination. It will be enough to set the upper diameter a few centimeters more than the bottom diameter. Largest doner shown above is approximately 350kg. Any smaller size of doner can be placed on robot.

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6.2 Doner Types - Shapes that cannot be cut using the robot

6.1.3 When a large diameter doner is placed, always use the additional 35 cm or 25 cm diameter bottom trays.

6.2.1 Doner in the figure will not be cut as it is not compliant with the robot’s software and hardware. The robot will not be able to finish the measurement and eventually switch to service mode with an error and start standby. A doner with this shape must not be cut with the robot.

6.2.2 Doner in the figure mostly occurs in veal, chicken or turkey meat that is not trimmed. After doner is prepared, it must be trimmed and layer ends must be corrected before placing on robot. With this shape of doner, cutting will start but robot will give error frequently.

Figure 38

Figure 396.2.3 Doner in the figure can be observed when it is placed on robot or during preparation. It is not suitable for cutting. Cutting will start from the middle part where diameter is the largest, but it will take some time for the robot to correct the surface. If this occurs after some time, contact your doner supplier.

Figure 40

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6.3 Points to Take into Consideration when Using the Grill6.3.1 Grill gets closer to doner as doner gets smaller towards the end of cutting. Condition in Figure 41-A occurs when grill covers are open. In this case, cutting arm will perceive the grill covers as obstacles as they get past the doner due to its operation logic. This means that grill doors will be detected as doner parts, cutting continues accordingly and it will give error. You need to close the covers as shown in Figure 41-B to prevent this. Besides, you can remove covers or move grill back so that covers stay behind doner. As a result, you need to ensure that covers do not get past the level of doner shaft.

Figure 41 - A Figure 42 - B

FALSE TRUE

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7.1 Hood

7 Mounting of Parts Supplied As Not Attached

- Positions of robot and hood during installation and required distances.

- Tray and front boiler are supplied separately.- Do not start the boiler without filling in 1.5 to 2 liters of water.

7.2 Bain-marie

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8 Mounting of Replaceable Parts8.1 Gas Nozzle

WARNING! Gas supply hose must be compliant with current national rules. It must be checked in stated maintenance periods and replaced if necessary.

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8.2 Mounting Gas Nozzle

8.3 Mounting Gas Valve

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For machines working 24 hours, doner grill wires are recommended to be replaced by the authorized service at least once a year.

WARNING! Unless otherwise stated, mounting personnel must not adjust the parts fixed by the manufacturer.

8.4 Radiant Mounting

8.5 Radiant Wire

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9 Potential Problems9.1 Robot does not work.

9.2 Controller does not work.

9.1.1 Check if the robot cable is plugged.

9.1.2 If it is plugged, check if pacco switch and emergency stop button are on. (Follow the steps in 2.1 Plugging and Starting Robot.)

9.1.3 If both are on, check if automatic fuses in the board are on.

9.1.4 There might be leakage in the system if fuses trip again after turned on. Contact technical service.

9.1.5 If all other conditions are correct, check timer light in the board. (Figure 15) Contact technical service if it is not lit.

9.2.1 If the robot has electricity but the controller does not work, replace the controller batteries.

9.2.2 Open the camera of your smartphone and point it towards the controller receiver. Press a controller key and check if it is lit through the smartphone camera. If the trans-mitter of the controller does not emit a signal, contact technical service. (You may not observe the signal even if it is emitted when using iPhone. )

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9.3 Robot does not start cutting.

9.4 Blade rotates with noise.

9.5 Robot rips doner.

9.3.1 Check if sensors are clean. Clean if there is a meat piece, oil or dirt on.

9.3.2 Clean if there is a residue such as meat, oil piece on the cutting blade.

9.3.3 After checking these, contact technical service if your robot still does not start cut-ting.

9.4.1 Remove blade, clean it and refit. Check if any piece of meat is stuck behind the blade and make sure it to turn freely.

9.5.1 Reset cutting. i.e. stop the operation and restart.

9.5.2 Your blade can be blunt. You need to sharpen it. (Follow steps in 2.2.4.)

9.5.3 Cutting thickness setting can be incorrect. Set the cutting thickness as in step 2.2.3 to desired condition.

9.5.4 Optical cutting thickness setting can be incorrect. Increase or decrease optical pres-sure as in step 3.3.3 and set the desired precision.

9.5.5 Contact technical service if you still cannot cut uniformly.

9.6 Robot exits the program.

9.7 Grill turns off.

8.6.1 Robot will exit cutting for all interventions made on cutting program when meat is left after the robot is set (3+1, nonstop, etc.). You just need to set the desired program while the arm is being lowered.

9.7.1 If the grill goes off when you release the button after being lit previously, thermo-couple must be faulty. Contact technical service.

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10 Spare Parts List

10.1 Gas Nozzle

10.2 Radiant Wire

10.3 Radiant

10.4 Thermocouple

10.5 Gas Valve

10.6 Valve Bakelite

10.7 Scanner + Receiver

10.8 Rotating motor (small)

10.9 Main board

10.10 Control board

10.11 Blade

10.12 Controller

Optionally, above parts can be sent as spare parts.

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11 Mounting Pictures

11.1 Cutting Arm

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11.2 Cutting Motor

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11.3 Y-axial Motor and Reducer

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12 Electrical Charts

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51

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13 Certificates

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14 Points to Take into Consideration in terms of Warranty

This warranty provided by IDM does not cover failures caused by using doner robot, doner grill, conveyor and lift outside their purpose of use as well as conditions stated below:

1. Damages and faults caused by use errors,

2. Damages and faults caused during loading, unloading and transport of the product after it is delivered to customer,

3. Damages and faults caused due to low or excessive voltage, faulty cabling or use with volt-age other than the voltage stated on product label,

4. Damages and faults caused by fire and lightning stroke.

5. Damages caused as product is not used in accordance with terms stated in operation manuals.

Abovementioned faults are repaired for a fee.

Warranty is valid for the time stated in this document and only for faults in the product and no claims or rights will be accepted under any names based on the warranty certificate.

Dealer, retailer, agency or representatives that the consumer buys the product from are responsible for submitting the warranty certificate to the customer. This warranty will be void if warranty certificate is damaged; original serial number on the product is removed or damaged.

Maximum Repair Period: 20 work days Warranty Period: 1 year

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15 Technical Service

You can contact the technical service via contact information below.

Address: Kemalpaşa Organize Sanayi Bölgesi 16. Sokak No: 5 35177 Kemalpaşa İzmir TURKEYTelephone: +90 232 877 1380Fax: +90 232 877 1390