Operations Quick Start Guide

Transcription

1 Loring Coffee Roasters All Models

2 Notices Document Versioning Information Date Last Exported: March 3, 2017 Loring Smart Roast, Inc. All rights reserved. The name LORING SMART ROAST, the Loring logo, and the catchphrase The Smarter Way To Roast are all trademarks of Loring Smart Roast, Inc. Warranty is void unless product is installed and used in accordance with all written instructions. This manual, along with other manuals in this series, is intended to be a guideline for the installation and use for the product lines manufactured by Loring Smart Roast, Inc. The customer is responsible for complying with all applicable regulations. The customer should refer to a licensed professional contractor or contractors for all installation details. Dangers, Warnings, and Cautions Throughout this manual, the following signal words are used to identify the degree of seriousness in any operation that presents a potentially hazardous situation. DANGER: Indicates a hazard that WILL cause severe personal injury, death, or substantial property damage if ignored. WARNING: Indicates a hazard that could cause SEVERE personal injury, death, or substantial property damage if ignored. CAUTION: Indicates a hazard that could cause MINOR personal injury or property damage if ignored. Page 2

3 Operations Quick Start Guide General Notes Follow all written instructions provided by Loring, and verbal instructions from Loring Customer Support, regarding site preparation prior to receiving the coffee roasting equipment. Do not operate the roasting equipment until after system commissioning by an authorized Loring Field Service Technician. Comply with all applicable rules and regulations and governing agencies, including workplace safety guidelines. Loring reserves the right to change information within this document at any time without notice. Page 3

4 Contents Introduction 9 Audience 9 About This Manual 9 Additional Documentation 10 Basic Safety Precautions 10 Roaster Components 12 Roaster Front Left View 13 Roaster Front Right View 14 Roaster Front View 15 Roaster Back Right View 16 Roaster Back Left View 17 Roaster with Destoner in Position 18 Daily Operations 20 Start of Each Day 20 Check Chaff Barrel 20 Turn On Roaster 21 Warm Up Roaster 24 Load and Connect Green Bean Cart (Optional) 26 Perform a Manual Roast 27 Start a Roast Dialog Settings for Manual Roast 27 Check for Readiness 29 Start a Manual Roast Cycle 30 During the Manual Roast Cycle 31 Controlling a Manual Roast 32 Towards the End of a Manual Roast 33 Manual Roast End of Roast (EoR) 34 Enter Post Roast Comments 35 Unload Roasted Beans from the Cooling Tray 36 Page 4

5 Perform a Profile Roast 37 Start a Roast Dialog Settings for Profile Roast 37 Profile Roast Starts Automatically 40 Wait Charge 41 Charge Green 42 Wait TAP 43 During Profile Roast 44 Post Roast 45 End of Each Day 46 Roaster Cool-Down 46 Turn the Roaster Off 48 General Operation 51 Common Tasks 51 Empty Chaff Barrel 51 Inspect Green Bean Cart Magnet 51 Drop Roasted Beans Out of Drum Chamber 52 Setting End of Roast (EoR) Temperature 52 Managing Burner Idle Temperature 52 Burner Percentage 53 Burner % Ranges 53 Burner % Text Field 53 Burner % Slider 54 Profile Management 55 Load a Different Roast Profile 55 Upgrading to LCS v2 55 Roast Profile vs. Burner Recipe 56 Key Features 56 Auto Air Cool 56 Cooler Fan 56 Roaster Logs 57 Matching Roast in Process to Baseline Profile 57 Idle High and Idle Low Temperatures 57 Auto Discharge Setting 57 Page 5

6 Machine States 58 Temperature Measures 60 Temperature Sensor Locations 60 Inlet Air Temperature 62 Return Air Temperature 62 Stack Temperature 62 High Temperature Limit Thermocouple 63 Bean Temperature 63 Process Temperature 63 Baseline Temperature 63 User-Configurable Settings 64 Accessing the Configuration Screens 64 Recipe Settings 65 Roaster Settings 67 Screen Settings 68 Setup Products Screen 70 Diagnostics Screen 71 Burner Settings Screen 72 System Settings Screen 73 Auto Air Cool Settings Screen 74 Auto Gate/Destoner Settings Screen (Optional) 75 Cold Stack Incinerator (CSI) Settings Screen (Optional) 76 Switching Between Imperial and Metric Units 77 Setting the Time and Date 77 Cleaning the Touchscreen 77 User Levels, Privileges, and Default Passwords 77 Alarms 78 Alarm History 79 Location of Purge Proximity Switch LEDs 80 Drop Door Override Push Button 81 Location of CAB and Gas Pressure Switches 82 High Temperature Limit Controller Reset Button 83 Warnings 84 Fault Conditions 87 Page 6

7 Consolet Control Buttons and Indicators 91 Fault Remediation Controls 92 QUENCH CHAFF Button 92 QUENCH PROCESS Button 92 MANUAL AIR COOL Button 92 Emergency Stop Push Button 93 Restart After Emergency Stop 94 Emergency Quench Valve 94 Smoke or Fire in Roaster 95 Ending A Roast Immediately 95 Recommended Maintenance 96 Basic Procedures for All Maintenance 96 Main Power Disconnect Switch 96 Daily Maintenance 97 Empty the Chaff Barrel Frequently 97 As Needed 97 Cleaning Roaster Surfaces 97 Oiling the Drum Paddle Bearings 97 Weekly Maintenance 97 Cleaning the Cooling Tray 97 Cleaning Under the Chaff Barrel Lid and in the Cyclone 98 Cleaning the Cooler Ducts 98 Cleaning the Mini Cyclone Cartage Filter 98 Cleaning the Auto Hopper Blower Vacuum Filter 99 Monthly Maintenance 99 Cleaning the Cyclone Spray Nozzle 99 Cleaning the Combustion Air Blower (CAB) Filters 100 Cleaning Behind the Drum Screen 100 Inspecting the Purge Gate 100 Every 2-6 Months 101 Cleaning the Cooler Fan 101 Deep Cleaning the Cooler Ducts 101 Page 7

8 Every 6 Months 102 Inspecting the Cooler Vent Stacks 102 Annual Maintenance 103 Cleaning the Green Bean Hopper 103 Inspecting the Drum Paddle Drive Bearings 104 Suggested Maintenance Schedule 105 Replacement Parts 106 Burner Tip and Electrode 106 Teflon Wipers 106 Cooling Tray Screen 106 Mini Cyclone Filter 106 Drum Paddle Bearings 106 Combustion Air Filters 106 1/2 Inch Fiberglass Adhesive-Backed Gasket Material Inch Fiberglass Adhesive-Backed Gasket Material 106 Cyclone Burner Sight Glass 106 Bean Thermocouple 106 Manufacturer Contact Information 107 Page 8

9 Introduction Audience The intended audience for this manual, the Operations Quick Start Guide, is anyone who is responsible for daily coffee roasting operations. It is assumed that the roaster operator is knowledgeable regarding the selection of appropriate bean products, and already has sufficient expertise to optimize roast quality. About This Manual This manual is organized in a quick start fashion, for roaster operators who want to begin roasting immediately. Prior to operating the roaster, each customer should have received onsite training from a Loring Field Service Technician as part of system commissioning. The basic steps in daily operations are: 1. Turn on utilities. Power on the roaster and run a Warm Up cycle. 2. Perform one Manual Roast to create a Roast Profile suited to the product, batch size, and desired roast level. 3. Perform one or more Profile Roasts based on the Manual Roast. 4. Cool down and turn off Roaster. Shut off utilities. After attaining familiarity with the use of Loring coffee roasting equipment, the roaster operator conducts daily operations as best fits the customer s individual needs. This manual applies to the S-family of Loring coffee roaster models. Some of these roaster models includes a Green Bean Cart as a separate accessory. Use of the Destoner, an optional piece of equipment, is not covered. CAUTION: Do not operate the roaster prior to system commissioning by an authorized Loring Field Service Technician. The commissioning includes onsite training in use and maintenance of the roaster. Turning on the roaster prior to commissioning will void the warranty. Instructions for basic procedures assume factory settings and defaults. Many of these settings are user-configurable. Page 9

10 Additional Documentation The following additional documentation is available from Loring. Contact your Loring Account Representative for more information. Pre-Installation and Site Preparation Guide. This guide outlines the steps that the customer must take prior to receiving the roaster. Installation and Assembly Guide. After receiving the coffee roaster, the customer must engage with a licensed general contractor to assemble, position, and hook up the roaster to various utilities and stack ventilation. Basic Safety Precautions DANGER: Failure to follow recommended basic safety precautions can result in severe injury or death. DANGER: Never reach inside the Drum Chamber while it is hot, or with the main power disconnect on, or while the Drum Paddle is running. Excessive heat and a potentially rotating Drum Paddle Drive could cause severe injury. DANGER: Never reach inside the Cooling Tray while the Mixer Paddle is operating, as injury may result. The Mixer can start automatically at certain points during the roast cycle. DANGER: Roasting operations should be carefully monitored at all times. The temperature at which beans ignite is only about 30 degrees F higher than the hottest allowable roasting temperature. DANGER: Use appropriate safety practices to avoid buildup of combustible gases inside and around the roaster, including locating the roaster in a well-ventilated area. DANGER: Use care when wearing loose clothing or long, loose, unbound hair around the roaster. Hair and clothing can become caught in moving equipment and cause severe injury. WARNING: The entire surface of the roaster is very hot while the roaster is in operation. Do not touch any surface on the roaster except the Tryer handle, the Consolet Touchscreen and control buttons, and the Cooling Tray Gate. Use caution around the roaster at all times. Page 10

11 Basic Safety Precautions, continued WARNING: The Cooler Ducting and the Cooler Fan can get very hot. Allow these components to cool before disassembling for cleaning. WARNING: The Tryer can get very hot. Always handle the Tryer by the wooden handle only. WARNING: If excessive amounts of smoke are present, take action to lower the roast temperature and use the Quench features or Emergency Stop as needed. The Cyclone includes an incineration feature that eliminates most smoke before it exits the roaster or the Stack, so there should not be excessive smoke at any point during roaster operation. The roaster also has built-in safety features and will issue a Machine Fault in the event that temperatures exceed allowable thresholds. CAUTION: Shut off the power using the Main Power Disconnect Switch on the roaster s Electrical Panel prior to performing maintenance. CAUTION: Do not allow unauthorized persons around the roaster. Keep children and animals well away from the roasting area at all times, especially while the roaster is operating. CAUTION: Do not allow the chaff level inside the Chaff Barrel to exceed the Full mark on the Chaff Barrel. CAUTION: Do not remove the Chaff Barrel while the Circulation Fan is running. CAUTION: Keep the area around the roaster clean and dry, and clear of obstructions as required by applicable safety regulations. CAUTION: Turn off power and close all utility valves when the roaster is not in use. Page 11

12 Roaster Components Roaster Front 1 Cooling Tray 21 2 Mixer 22 Right Side Chaff Barrel Green Bean Cart 3 Tryer 23 Green Bean Cart Magnet 4 Work Light 24 Green Bean Cart Vacuum Hose 5 Cooling Tray Gate 6 Roaster Door 7 Bean Temperature Sensor 8 Viewing Window Roaster Back 9 Green Bean Hopper 25 Cyclone Interior Drum Chamber Drum Paddle Cyclone Sight Glass Stack Temperature Sensors Cooler Fan Circulation Fan Left Side 30 Auto Hopper Blower Return Air Temperature Sensor Return Air Temperature Gauge Consolet Operator Touchscreen Auto Hopper Blower Filter Housing Purge Gate Purge Gate Air Cylinder Purge Gate Proximity Switch LED Indicators 16 Operator Controls 35 Emergency Quench Valve 17 Drop Door Override Push Button 36 Inlet Air Temperature Sensor 18 Emergency Stop Push Button 37 Mini Cyclone Utility Valves Main Power Disconnect Switch 38 Combustion Air Blower (CAB) Pressure Switch LED Page 12

13 Roaster Front Left View 1 Cooling Tray 15 Operator Touchscreen 2 Mixer 16 Operator Controls 3 Tryer 17 Drop Door Override Push Button 5 Cooling Tray Gate 19 Utility Valves 6 Roaster Door 20 Main Power Disconnect Switch 7 Bean Temperature Sensor 22 Green Bean Cart 8 Viewing Window 24 Green Bean Cart Vacuum Hose 9 Green Bean Hopper 25 Cyclone 10 Drum Chamber 30 Auto Hopper Blower Back Left Front Page 13

14 Roaster Front Right View 1 Cooling Tray 21 Chaff Barrel 2 Mixer 22 Green Bean Cart 3 Tryer 24 Green Bean Cart Vacuum Hose 5 Cooling Tray Gate 25 Cyclone 6 Roaster Door 8 Viewing Window 9 Green Bean Hopper 10 Drum Chamber Back Front Right Page 14

15 Roaster Front View Tryer Work Light Roaster Door Bean Temperature Sensor Viewing Window Return Air Temperature Sensor Operator Touchsccreen 3 16 Operator Controls Power On/Off Selector Switch Emergency Stop Push Button Front View Page 15

16 Roaster Back Right View 1 Cooling Tray 29 Circulation Fan 9 Green Bean Hopper 30 Auto Hopper Blower 10 Drum Chamber 31 Auto Hopper Blower Filter Housing 21 Chaff Barrel 32 Purge Gate 22 Green Bean Cart 33 Purge Gate Air Cylinder 23 Green Bean Cart Magnet 34 Purge Gate Proximity Switch LED Indicators 24 Green Bean Cart Vacuum Hose 35 Emergency Quench Valve 25 Cyclone 36 Inlet Air Temperature Sensor 26 Cyclone Sight Glass 37 Mini Cyclone 27 Stack Temperature Sensors Front Right Back Page 16

17 Roaster Back Left View 1 Cooling Tray 27 Stack Temperature Sensors 2 Mixer 28 Cooler Fan 9 Green Bean Hopper 29 Circulation Fan (Housing) 10 Drum Chamber 30 Auto Hopper Blower 15 Operator Touchscreen 31 Auto Hopper Blower Filter Housing 17 Drop Door Override Push Button 32 Purge Gate 19 Utility Valves 21 Chaff Barrel 24 Green Bean Cart Vacuum Hose Emergency Quench Valve Inlet Air Temperature Sensor Mini Cyclone 25 Cyclone Front Back Left Page 17

18 Roaster with Destoner in Position The Destoner is an optional piece of equipment that removes stones and other debris from beans after roasting. If used, the Destoner remains in position, so that the opening in the Destoner Hopper is aligned with the Cooling Tray Gate. Back Destoner Front Right Page 18

19 Roaster with Destoner in Position, continued Cooling Tray Gate (closed position) Roaster Destoner Destoner Front Left View The Cooling Tray can be rotated to a desired position. The Destoner position follows the placement of the Cooling Tray Gate, as described in the Pre-Installation Guide. Page 19

20 Daily Operations These instructions assume that you have already received basic operator training from a Loring Field Service Technician. Start of Each Day At the start of each day, the roaster is assumed to be powered off, with water, gas, and air valves shut off. Check Chaff Barrel As a matter of precaution, check the Chaff Barrel and make sure the chaff level is below the Full mark on the Chaff Barrel. If the chaff level exceeds this mark, empty the Chaff Barrel and replace before continuing. Rotate or lift clip to release Chaff Barrel Lid. For Chaff Barrels supported by spring mounted wheels, press down on Chaff Barrel to move. Chaff Barrel Lid clips may vary Chaff Barrel Full level Page 20

21 Turn On Roaster 1. Turn on utilities: water, gas, air. Turn on the Main Power Disconnect Switch. The exact configurations for the utility valves may vary by roaster model. Utilities can be identified by color as follows: Air White Water Blue Gas Yellow Compressed Air Valve Water Valve 90 degrees counterclockwise to open Off On Natural Gas or Propane Valve Utility Valve Closed The Main Power Disconnect Switch is located on the outside of the roaster s Electrical Panel on the left side of the roaster. Utility Valve Open Page 21

22 2. Rotate the Power On/Off Selector Switch 90 degrees clockwise to power on the roaster. The Power On/Off Selector Switch is located on the front of the Consolet. When rotated on, it springs back to upright, and a green LED illuminates on the switch itself. Allow approximately seconds for the roaster startup sequence to display on the Touchscreen. When the Main Roast Screen displays, the roaster s Machine State displays as Ready in the upper right corner of the Touchscreen. If the Main Power Disconnect Switch is off, turn on first prior to powering on the roaster. This switch is located on the Electrical Panel. Rotate 1/4 turn clockwise so that it points straight up. Touchscreen 90 degrees clockwise Power On/Off Selector Switch The Initialization screen displays momentarily. If the screen does not advance to the Main Roast Screen, contact Loring Customer Support. Page 22

23 Figure 1. Main Roast Screen After Power On Menu button leads to Configuration screens Tap the WARM UP button to begin roaster Warm Up cycle Machine State displays as Ready Page 23

24 Warm Up Roaster 1. Tap the WARM UP button on the Touchscreen. Typically this takes around 30 minutes, depending on the user-configurable Idle High and Idle Low Temperatures. The WARM UP button changes color from black to green, and shows Warming Cycle. The roaster cycles through several Machine States such as Purge, Ignite, and Stabilize, and executes 3 Warming Cycles to ensure even temperature distribution. 2. While the roaster is warming up, prepare to start the first roast of the day. A typical task would be loading the Green Bean Cart with the first load of beans. 3. When the WARM UP button changes to black and Machine State shows as Idle, the Warm Up cycle is complete. Figure 2. Main Roast Screen During Warm Up Cycle The WARM UP button displays green, showing Warming Cycle. The number indicates the number of cycles remaining. Page 24

25 Figure 3. Main Roast Screen After Warm Up Cycle Completed Page 25

26 Load and Connect Green Bean Cart (Optional) Some roaster models do not ship with a Green Bean Cart, and the operator lifts green beans from a smaller container instead. 1. Load the Green Bean Cart with green beans for the first roaster batch of the day. Use the Scale on the Green Bean Cart or other weighing device to measure the appropriate batch weight, which varies by roaster model and the desired roasting characteristics. Use the Maximum and Minimum Batch Size for the roaster model as a guide. These specifications can be found on the Loring web site. 2. Move the Green Bean Cart back to the roaster and connect the Green Bean Hopper Vacuum Hose. Ensure that Clip is folded inside, and contacts the Vacuum Hose Connection. Green Bean Hopper Vacuum Hose Vacuum Hose Connection Power On Scale controls may vary Green Bean Cart Tap the Power On button to turn Scale on. Once, powered, tap the button to switch between lbs and kg. Tap and hold to power off the scale. Page 26

27 Perform a Manual Roast Make sure the roaster is warmed up. Ensure that the roaster is connected to the Green Bean Cart or that another receptacle is present, and is loaded to the desired batch size. Start a Roast Dialog Settings for Manual Roast 1. Tap the LIFT GREEN button. This causes the Auto Hopper Blower at the back of the roaster to start up and draw the green beans up from the green bean receptacle and into the Green Bean Hopper, a process that typically takes around 1-2 minutes. This cycle is time-based, not based on weight or sensors to detect green bean location. The LIFT GREEN button turns green during the Lift cycle and shows a countdown timer in seconds. If all the green beans are lifted before the timer expires, tap the LIFT GREEN button again to stop the Auto Hopper Blower. 2. Tap the START A ROAST button at the top left the Main Roast Screen. The Start a Roast dialog appears. The choices differ based on whether you are doing a Manual or a Profile Roast. 3. Choose LOAD MANUAL ROAST at the top (optional). 4. Enter the batch size (weight) of the green beans loaded in the Green Bean Hopper. 5. Enter a Charge Temperature or tap COPY to accept the suggested Charge Temperature. The Charge Temperature is the desired Return Air Temperature at which green beans will enter the Drum Chamber from the Green Bean Hopper above the roaster. For Manual Mode, the roaster operator is responsible for charging the green beans manually with reference to this temperature. The Suggested Charge Temperature is calculated based on the Batch Size. There is a Batch Size Correction Calculator found in the Roaster Settings Configuration Screen, from which the Suggested Charge Temperature values are derived. 6. Choose an Initial Burner setting or tap COPY to accept the suggested setting. The Initial Burner Setting is the desired Burner Percentage to which the roaster will go to after the Drum Chamber is charged with green beans. The suggested Initial Burner Setting is calculated based on the batch size. 7. If the AIR COOL button shows a check mark, tap it once to de-select it. 8. Set End of Roast (EoR) target temperature. 9. Tap the START A ROAST WITH MANUAL CHARGE button. This closes the Start a Roast dialog and returns you to the Main Roast Screen. (Manual Roasts can also be started with an Auto Charge feature by selecting START A ROAST WITH AUTO CHARGE button, as explained in the Profile Roast section.) Page 27

28 Figure 4. Start a Manual Roast, Dialog Settings De-select Page 28

29 Check for Readiness The Main Roast Screen displays as follows when the roaster is ready to roast: 1. The WARM UP button changes from green back to black. 2. The BURNER button displays green with text Burner On and Flame On, with an icon of the Loring logo flame. 3. The CIRC FAN button displays green, Locked, with the Circulation Fan running. 4. The DRUM button displays green, Locked, with the Drum Paddle rotating inside of the Drum Chamber. 5. The Machine State displays as Idle in the upper right. 6. The roast type displays according to what was selected in the Start a Roast dialog. For example, Manual, Profile or Burner. 7. Verify there are beans in the Green Bean Hopper. Figure 5. Ready to Roast, After Initial Warmup Complete Page 29

30 Start a Manual Roast Cycle 1. Wait until the Return Air temperature matches what you entered for Charge Temperature on the Start a Roast dialog. It should be very close, within 10 degrees F (6 degrees C) of desired. If Return Air is too warm, use the MANUAL AIR COOL button (tap once to start, watch the temperature, tap again to stop). 2. Tap the CHARGE GREEN button. This causes the Green Bean Hopper on top of the roaster to charge the green beans into the Drum Chamber, and also initiates the roast cycle. The WARM UP button disappears from the screen. Figure 6. Main Roast Screen, During Charge Green 1 2 Page 30

31 During the Manual Roast Cycle A roast cycle can range between 8 minutes up to a maximum of 20 minutes, depending on batch size, desired start and stop temperatures, and other factors. 1. A real-time Roast Profile Graph appears on the Main Roast Screen, showing the Bean Temperature and progress of the manual roast cycle. Depending on how high the Burner is running, the roast cycle proceeds faster or slower, until the End of Roast (EoR) Temperature is reached. 2. A horizontal green bar across the top shows the End of Roast (EoR) Temperature. This bar turns white when the Bean Temperature approaches the EoR Temperature. 3. The Bean Temperature displays in the upper left. 4. The Rate of Rise (RoR) displays in the upper left (degrees per minute). 5. The End of Roast predictor is a vertical green bar which shows the estimated End of Roast (EoR) time, based on the Rate of Rise (RoR). This value will be constantly updating, based on the everchanging Rate of Rise. Figure 7. Main Roast Screen, During Manual Roast Page 31

32 Controlling a Manual Roast The roaster operator can control a manual roast cycle as follows: 1. Use the Roast Burner % field to throttle the Burner up or down at any point during the roast cycle. 2. Use the Burner Slider to adjust the Burner based on the current allowable range. 3. You can change the End of Roast (EoR) temperature mid-roast. 4. You can drop the End of Roast (EoR) temperature down to the current Bean Temperature in order to end a roast quickly, in the case of a Fault or Warning during the roast, or at the discretion of the roaster operator. 5. Tap the LOG COLOR, LOG 1st CRACK, and LOG 2nd CRACK buttons to record the time that these events occur during the roast. The same button changes name as each event is logged. (This step is optional depending on which of these buttons are activated in the Screen Settings Configuration Screen.) Figure 8. Main Roast Screen, Controlling a Manual Roast Page 32

33 Towards the End of a Manual Roast When the End of Roast (EoR) temperature is close to being reached, the following things occur: 1. The Cooler Fan starts drawing air down through the Cooling Tray, and the Mixer Paddle in the Cooling Tray begins rotating. This occurs a specified number of degrees below End of Roast (EoR) temperature, and runs for a specified amount of time. Both settings are configurable on the Roaster Settings Configuration Screen. 2. The End of Roast (EoR) bar across the top of the screen turns white. 3. The alarm buzzer sounds several beeps or chirps. Figure 9. Main Roast Screen, Manual Roast, Approaching EoR EoR line changes color 2 Page 33

34 Manual Roast End of Roast (EoR) At the End of Roast (EoR) for a Manual roast, the following things occur: 1. The Machine State changes to Post Roast. 2. The DROP ROASTED button turns green and shows Open. The Roaster Door opens, and the roaster automatically ejects the roasted beans from the Drum Chamber into the Cooling Tray. If the Roaster Door does not open automatically (configurable), tap the DROP ROASTED button. 3. The MIXER and COOLER FAN buttons turn green. The Mixer Paddle stirs the roasted beans in the Cooling Tray while the Cooler Fan draws room-temperature air down and through the Cooling Tray. The bean-cooling cycle lasts approximately 4 minutes, and shuts off automatically. The Cooler Fan Run Time is configurable on the Roaster Settings Configuration Screen. 4. The QUENCH CHAFF button turns green. The Auto Chaff Quench feature turns on, and activates a brief cooling jet of water into the Chaff Barrel to quench any smoldering embers that may be present. This is configurable on the Roaster Settings Configuration Screen. 5. The Roast Comments screen appears. Figure 10. Main Roast Screen, Manual Roast, Post Roast Cooling Page 34

35 Enter Post Roast Comments At the end of every roast cycle, the Enter Roast Comments dialog appears. If this roast was satisfactory, you can use this screen to save the manual roast as a new Roast Profile, Burner Recipe, or Baseline You can also enter other notes and observations for the roaster log, even if you choose not to save a new Profile. 1. Enter up to 3 comments in the Roast Comments fields. 2. To save, tap the LEAVE AND CAPTURE THIS ROAST button, and finish saving in the Recipe Settings Configuration Screen. 3. To leave without saving any roast data, tap the DONE button. This clears the data from this roast. Roast data will be ed, if that feature is enabled in the Screen Settings Configuration Screen. Figure 11. Main Roast Screen, Enter Post Roast Comments 1 2 Save the roast to a new Roast Profile 3 Saves comments, but does not save a new Roast Profile Page 35

36 Unload Roasted Beans from the Cooling Tray After the bean-cooling cycle is completed, The roaster operator can unload the roasted beans, either into the Destoner Hopper or into another container. 1. Make sure a receptacle is positioned below the Cooling Tray Gate. 2. Tap the MIXER button on the Main Roast Screen to re-start the Cooling Tray Mixer. 3. Raise the Cooling Tray Gate to open. The Mixer Paddles push the roasted beans out of the Cooling Tray as they rotate. 4. When the Cooling Tray is empty, close the Cooling Tray Gate. 5. Tap the MIXER button to shut off the Mixer. 2 Tap Cooling Tray Gate 1 Receptacle 3 Raise Page 36

37 Perform a Profile Roast These instructions assume that you have captured at least one Manual Roast, the roaster is already running and warmed up. Ensure that the roaster is connected to the Green Bean Cart or that another receptacle is present, and is loaded to the desired batch size. Tap the LIFT GREEN button to lift green beans from the container into the Green Bean Hopper on top of the roaster. Tap the START A ROAST button in the upper left of the Main Roast Screen. Start a Roast Dialog Settings for Profile Roast Your choices in the Start a Roast dialog for a Profile Roast will differ from those used for doing a manual roast. 1. Tap the LOAD PROFILE ROAST button. 2. The Select the File Dialog opens with a list of saved profiles. Choose the desired profile from the list. 3. Enter the batch size (weight). 4. Tap COPY to accept the suggested Charge Temperature, or enter the desired Charge Temperature. The Bean Charge Temperature is calculated by the roaster based on the Batch Size. The Charge Temperature is the Return Air Temperature at which green beans will enter the Drum Chamber from the Green Bean Hopper above the roaster. 5. Tap COPY to accept the suggested Burner setting or enter the desired Initial Burner setting. 6. Tap the AIR COOL button to select it (optional). This activates the Auto Air Cool feature. When enabled, the Auto Air Cool feature opens the Purge Gate at the back of the roaster, and ramps the Burner to 100% at a specified number of degrees before the End of Roast (EoR). This is known as the Trigger Temperature. The Auto Air Cool runs for the specified number of seconds. 7. Specify an Auto Air Cool Trigger Temperature. 8. Set a Time in seconds for the Auto Air Cool to run. 9. Enter the End of Roast (EoR) target temperature. 10. Tap the RUN AS PROFILE ROAST button to run the roast with automated (PID) control. 11. Tap the START A ROAST WITH AUTO CHARGE button in preparation for the roast cycle. Page 37

38 Figure 12. Start a Roast Dialog, Profile Settings Page 38

39 Figure 13. Start a Roast Dialog, Select the File 2 Tap to select a roast profile from the list Page 39

40 Profile Roast Starts Automatically For all roasting methods, use of the START A ROAST WITH AUTO CHARGE button causes the roast cycle to start automatically when the Return Air Temperature reaches the specified Charge Temperature. The roaster goes through several Machine States at the start of a Profile Roast: 1. Charge Cooling. If the Return Air Temperature is higher than the specified Charge Temperature, the Purge Gate opens, bringing in room-temperature air to cool the roaster. The Burner ramps to 100% in order to cool the roaster, and the Machine State changes to Charge Cooling. Once the Return Air Temperature drops below the specified Charge Temperature, the roaster continues to cool until the Return Air Temperature reaches the Auto Trigger Cooling Turnaround Temp Setpoint. This set point is user-configurable, on the Burner Settings Configuration Screen. After this set point is reached, the Purge Gate closes, the Burner drops to 20%, and the Machine State shows Wait Charge. 2. Wait Charge. The roaster is waiting for the Return Air Temperature to reach the specified Charge Temperature before allowing green beans to exit the Green Bean Hopper and enter the Drum Chamber. 3. Charge Green. Green beans are dropping from the Green Bean Hopper and entering the Drum Chamber. 4. Wait TAP. Immediately after the green beans drop, the Bean Temperature drops until the beans begin to warm up. During this Machine State, the Burner % will be the Initial Burner Setting. The Turn Around Point (TAP) is the point where the Bean Temperature stops decreasing, and begins to increase. 5. Profile Roast. The Profile Roast graph plots against the Baseline. 6. Auto Air Cool. The Machine State for Auto Air Cool occurs towards the End of Roast (EoR) based on the specified Auto Air Cool Trigger Temperature before the End of Roast (EoR) Temperature, and lasts for the Time specified in the Start a Roast dialog. A shorter Auto Air Cool time (15-30 seconds) helps to reduce the amount of smoke emitted from the Drum Chamber when the beans are discharged into the Cooling Tray. Longer Auto Air Cool times ( seconds) allow for darker roasts to be achieved by extending the roasting times. 7. Post Roast. Enter roast comments. Note that you can capture this roast as a new Profile Roast if desired. Page 40

41 Wait Charge During the Wait Charge Machine State, the screen appears as shown. 1. The Auto Charge Temperature line (yellow) displays. This is the Charge Temperature from the Start a Roast dialog. When the Return Air Temperature reaches this line, the roaster will charge. 2. You can abort Auto Charge mode by pressing the yellow AUTO CHARGE PRESS TO CANCEL button if you don t want to wait for the Auto Charge Temperature, or you want to use the manual CHARGE GREEN button instead. 3. A graph of the current Return Air Temperature displays in yellow. When this line reaches the Auto Charge Temperature line, the roaster s Machine State changes from Wait Charge to Charge Green. Figure 14. Main Roast Screen, Profile Roast, Wait Charge Page 41

42 Charge Green The Charge Green Machine State occurs during Manual, Profile, or Burner Recipe roasts, as the green beans are entering the Drum Chamber from the Green Bean Hopper. Figure 15. Main Roast Screen, Profile Roast, Charge Green Page 42

43 Wait TAP During Wait TAP, the screen appears as shown. 1. The yellow Auto Charge Temperature line changes to show a green End of Roast (EoR) temperature. 2. The white profile graph represents the Baseline for the Roast Profile that will be followed during the roast. 3. The green profile graph shows the Bean Temperature in real-time. Figure 16. Main Roast Screen, Profile Roast, Wait TAP Page 43

44 During Profile Roast During a Profile Roast, the Main Roast Screen appears as shown. 1. The white profile graph represents the Baseline (Roast Profile) that will be followed during the roast. 2. The green graph shows the current Bean Temperature of the roast in process, real-time. 3. The current Bean Temperature displays in the upper left. 4. The Roast Burner % Slider display changes to a read-only mode. This value is controlled by the roaster and varies in order to follow the baseline. 5. The Delta Temperature (ΔT) shows the difference between the Process Temperature (actual Bean Temperature) and the Baseline Temperature (the Profile). 6. You can press the blue CHANGE TO MANUAL button at any time to abort the Profile Roast and switch to Manual roast mode, in order to exercise manual Burner control during the roast. Once manual roast has been initiated, the Roast Burner % must be monitored and adjusted by the roaster operator. Figure 17. Main Roast Screen, Profile Roast, During Roast Page 44

45 Post Roast The Post Roast Dialog that appears at the end of a Profile Roast is the same as what appears at the end of a Manual Roast. Enter comments as needed and tap the DONE button to exit this screen. Figure 18. Main Roast Screen, Profile Roast, Post Roast Page 45

46 End of Each Day At the end of each work day, it is recommended to cool down and then turn the roaster completely off, including utilities. It is also recommended to empty the Chaff Barrel at the end of each work day. Roaster Cool-Down Use the following recommended cool-down sequence when powering down the roaster at the end of the day. 1. Tap the COOL DOWN button at the top of the Main Roast Screen. 2. The COOL DOWN button turns green and shows as COOLING DOWN. 3. Machine State changes to Cooldown. 4. Both the Roaster Door and the Purge Gate open. The DROP ROASTED button turns green and shows as DROP ROASTED OPEN. 5. The Drum Paddle stays on, and the DRUM button turns green. 6. Both the AUTO AIR COOL and MANUAL AIR COOL buttons turn green. 7. The Burner shuts off. 8. The Circulation Fan ramps up to high speed, and the CIRC FAN button turns green. Page 46

47 Figure 19. Main Roast Screen, Cool Down Mode Page 47

48 Turn the Roaster Off 1. Monitor the roaster s temperature sensors during Cool Down. When Return Air, Inlet Air, and Bean Temperature are all below 160 degrees F (71 C), Cooldown mode is complete. The roaster is now ready to be powered off. Figure 20. Main Roast Screen, Cool Down Complete 1 Page 48

49 Turn the Roaster Off, continued 2. Turn the Power On/Off Selector Switch 90 degrees counterclockwise. This switch is located on the Consolet. The green LED on the Power On/Off Selector Switch turns off. 90 degrees counterclockwise Power On/Off Selector Switch Page 49

50 Turn the Roaster Off, continued 3. Turn off utilities: water, gas, air. Shut off the Main Power Disconnect Switch. The exact configurations for the utility valves may vary by roaster model. Utilities can be identified by color as follows: Air White Water Blue Gas Yellow Compressed Air Valve Water Valve 90 degrees counterclockwise to open On Off Natural Gas or Propane Valve Utility Valve Closed The Main Power Disconnect Switch is located on the outside of the roaster s Electrical Panel on the left side of the roaster. Utility Valve Open Page 50

51 General Operation This section contains general notes on roaster operation, including frequently performed tasks, and important operational features. Common Tasks Empty Chaff Barrel The Chaff Barrel should be emptied before it is at the Full Mark. To empty the Chaff Barrel: 1. Tap the BURNER button to shut off the Burner. 2. Tap the CIRC FAN button to shut the Circulation Fan off. 3. Open the Clamps (or clips) on the Chaff Barrel Lid, which is permanently attached to the Cyclone. The Chaff Barrel may be on spring-loaded wheels. 4. For Chaff Barrels on spring-loaded wheels, hold the Chaff Barrel Handles, and press down on the Chaff Barrel to release it for transport. WARNING: Do not empty the Chaff Barrel while the Circulation Fan is running or the Burner is on. Inspect Green Bean Cart Magnet The Green Bean Cart has a Magnet at the bottom of the Hopper. This is not attached, and can be lifted out. Inspect underneath as well as the top side. Remove debris as necessary. Do not allow Magnet to adhere to ferrous surfaces. Note: Magnet may be square in shape or round, depending on Green Bean Cart model. Page 51 Green Bean Cart Magnet

52 Drop Roasted Beans Out of Drum Chamber By default, beans are discharged automatically from the Drum Chamber into the Cooling Tray at the End of Roast (EoR). However if the Auto Discharge feature is turned off using the AUTO DROP AT EoR (Enable button) on the Roaster Settings Configuration Screens, you can open the Roaster Door and eject the beans in one of the following ways: Tap and hold the DROP ROASTED button on the Main Roast Screen. For faster or immediate response, use the Drop Door Override Push Button on the left side of the roaster frame, immediately next to the Cooling Tray. This is a mechanical push button. If Auto Drop is enabled on the Roaster Settings Configuration Screen, roasted beans will eject automatically. Setting End of Roast (EoR) Temperature The End of Roast (EoR) temperature is set individually for each roast, in one of the following ways: Do a manual roast. On the Start a Roast dialog, choose the MANUAL ROAST button, and enter the End of Roast Target Temperature. For a Profile Roast, use the Recipes Settings Configuration Screen. You can override the Profile s EoR Temperature on the Start a Roast dialog. On the Main Roast Screen, you can directly edit the EoR text field while a roast is in progress. Managing Burner Idle Temperature To ensure even thermal distribution, the Drum Paddle should be left rotating inside the Drum Chamber as long as the Return Air, Inlet Air and Bean Temperatures are above 160 degrees F (71 C). Use the DRUM button on the Main Roast Screen to turn the Drum Paddle on and off. While the Burner is lit, the roaster will not allow the user to turn off the drum. This is indicated by a lock icon on the DRUM button. CAUTION: The roaster can be in a Machine State of Idle for long periods of time between roasts. The roaster can get very hot. Without the Drum Paddle turning, localized heat buildup inside the Drum Chamber can lead to uneven thermal expansion, which can damage roaster components. Page 52

53 Burner Percentage The Burner Percentage field is a real-time indicator of the intensity at which the Burner is operating when compared with its maximum output for the current Machine State. The Roast Burner % Slider on the Main Roast Screen allows a roaster operator to throttle the Burner up or down to make fine-tuned temperature adjustments during a Manual Roast cycle. Note that adjustment of the Burner Percentage is disabled during Burner Recipe and Profile Roast cycles. When the roaster is in Idle state, the Roast Burner % shows as 0% even though the Burner is on. The Burner output cannot be adjusted during a Profile Roast. To change it, tap the CHANGE TO MANUAL button. Burner % Ranges There are two ranges of Burner Output Percentage, based on whether the roaster is in a Machine State of Idle, or is actually roasting (Machine State displays as Manual Roast, Profile Roast, or Burner Recipe ). They represent different Burner Output Percentage levels. Idle Burner Percentage. This range is active when the roaster is in a Machine State of Idle, and allows input from 0 to 100%. This is a reduced or limited operating range of the Burner Output to allow safe operation when the Drum Chamber is empty. In this range:»» 0% represents the minimum Burner output for which the Burner remains lit (on) in a Machine State of Idle.»» 100% represents the maximum reduced Burner Output in the Idle Machine State. This value cannot be changed or adjusted. Roast Burner %. This range allows an input from 20 to 100%. This is an expanded operating range of the Burner Output to utilize the full thermal potential of the roaster during a roast, when the Drum Chamber contains a load of beans. In this range:»» 20% represents the minimum Burner output for the roaster.»» 100% represents the maximum Burner output for the roaster. Burner % Text Field Tap the Burner % text field to enter a new Burner Percentage. Use the data entry virtual keypad to enter the desired percentage. The name of this field changes depending upon the Roast Mode and the Machine State. For example, it displays as Idle % when the roaster is in the Idle Machine State. Page 53

54 Burner % Slider You can use the Burner % Slider to increase or decrease the Burner % across a predefined range. The Slider appears on the right-hand side of the Main Roast Screen. The numbered scale on the Slider changes depending on the Machine State that is currently active.»» Roasting During Manual Roast mode, the scale is % and is editable. During Profile Roast, it displays but is not editable.»» Idle the Slider is present, but the delineation numbers do not display.»» Charge Green Burner goes to 20% and the Slider disappears. Slider features:»» Touch the Slider to re-set the scale to that point.»» Tap the up or down arrow icons to set the Burner to maximum (always 100%) or minimum (variable). Note that minimum may change depending on Machine State. Figure 21. Roast Burner % Sliders During Idle, Manual Roast, and Profile Roast Text Field Up Arrow Slider Down Arrow Idle Manual Roast Profile Roast Page 54

55 Profile Management Roast Profiles are the primary means of managing predefined roast temperature curves. Legacy users should note the addition of an enhanced feature available for upgrade through new roaster controller software (LCS v2). The Profile Roasting feature allows better control than the previous Roast Profile method. The Burner Recipe feature is still available after upgrading. Load a Different Roast Profile You can load any Roast Profile that is saved in the system as follows: 1. From the Main Roast Screen, tap the MENU button. 2. The Roaster Settings Configuration screen appears. 3. Tap the RECIPES button on the left. 4. The Recipe Settings Configuration Screen appears. 5. Tap the LOAD button on the left. 6. Select desired Roast Profile in the Select the File Dialog. 7. Tap START THIS ROAST button on the top right to return to the Main Roast Screen. Figure 22. Select the File Dialog Upgrading to LCS v2 Legacy users must request an upgrade in order to use Profile Roasting. Software upgrade is not automatic, nor is it required. Please contact Loring for more information on upgrading, if desired. Page 55

56 Roast Profile vs. Burner Recipe The differences between Profile Roasting and Burner Recipes are as follows: Burner Recipes work based on Bean Temperature and Burner Percentage. At a specific Bean Temperature, the system adjusts the Burner Percentage to a predefined amount. Profile Roasting constantly monitors bean temperature, and automatically adjusts the Burner Percentage to follow a Baseline curve. This achieves a predetermined bean temperature at any given time, resulting more granular temperature control, and repeatability of roast results regardless of batch size. Roast Profiles and Burner Recipes are transferable between roaster models. Roast Profiles are scalable to different batch sizes, while Burner Recipes are not. Key Features This section provides information on key features of the Loring roaster family. Auto Air Cool When enabled, the Auto Air Cool feature opens the Purge Gate at the back of the roaster, and ramps the Burner to 100% at a specified number of degrees before the End of Roast (EoR). You can enable and change settings on the Auto Air Cool Configuration Screen. This is a smoke abatement feature that reduces the amount of Cooling Tray smoke by incinerating it before the roast is finished. Cooler Fan The Cooler Fan activates under the following conditions: You can manually turn on the Cooler Fan at any time by tapping the COOLER FAN button on the Main Roast Screen. The AUTO DROP button on the Roaster Settings Configuration Screen enables a feature that opens the Roaster Door automatically at the End of Roast (EoR). If enabled, Auto Drop also turns on the Cooler Fan for a time period specified on Roaster Settings Configuration Screen. The Cooler Fan turns on a specified number of degrees below End of Roast (EoR) Temperature, as defined on the Roaster Settings Configuration Screen. The Cooling Tray Mixer Paddle and the Cooler Fan turn on automatically when the Roaster Door opens at the end of a roast. They do not turn on if the Roaster Door is opened outside of a roast (a Machine State of Idle or Ready ). Page 56

57 Roaster Logs Data on each roast is captured as follows: Data on each roast cycle is saved in a temporary log on the roaster itself. If is enabled on the Screen Settings Configuration Screen, roast data is ed to specified recipients. This clears at the end of every roast so only the previous roast s data is sent. You can save the roaster data permanently for future reference by using the LEAVE AND CAPTURE button on the Enter Roast Comments screen that appears at the End of Roast (EoR).»» You must enter your roast notes before pressing the LEAVE AND CAPTURE button.»» Enter a Profile Name to save it as re-usable Roast Profile for future use.»» No roasts are stored on the roaster unless you Capture and save it. Otherwise, the roast log is cleared at the end of the current roast. Matching Roast in Process to Baseline Profile When a Roast Profile is loaded, the actual roast in process is plotted against the Baseline represented by the Profile. Refer to the Delta T (Δ T) indicator on the Main Roast Screen and the visual graph to see how closely the Process is following the Baseline. You can switch to Manual Roast mode at any point in order to use the Roast Burner % Slider for manual throttling of the Burner. Tap the CHANGE TO MANUAL button on the Main Roast Screen. Idle High and Idle Low Temperatures When the roaster is in a Machine State of Idle, the Burner remains on. The roaster cycles between an Idle High and Idle Low Temperature, in a user-configurable range. The display shows a Machine State of Thermal Standby Cool when cooling down from Idle High to Idle Low. Auto Discharge Setting The Auto Discharge feature is enabled using the Auto Drop at EoR field on the Roaster Settings Configuration Screens. This feature causes roasted beans to be discharged automatically from the Drum Chamber into the Cooling Tray at the End of Roast (EoR). Page 57

58 Machine States Table 1. Roaster Machine States Machine State INIT Ready Purge Ignite Stabilize Idle Thermal Standby Cool Wait Charge Notes Initialization state when roaster is powered on. Displays after roaster is powered on, or when the Burner flame is off and there are no active Machine Faults. Indicates that the roaster is ready for the operator to light the Burner. Displays immediately before flame ignition, after the operator taps the BURNER button. Indicates that the roaster is preparing to light the Burner by replacing the flammable, indeterminate, or high-oxygen-bearing atmosphere with air which results in a non-flammable final state inside the roaster. During this state, the Burner flame is still off, the Purge Gate is open, and the Circulation Fan Motor is running at maximum speed. Displays when the Burner is being ignited, while the ignitor is arcing. Occurs after Ignite. This is a set time period to verify that Burner flame is stable, i.e., a proving period for flame integrity. The Purge Gate is closed. Normal operating state between roasts. The Burner flame is on. This Machine State persists until the Idle High temperature is reached, at which point Machine State changes to Thermal Standby Cool. If the operator shuts off the Burner flame, Machine State changes to Ready. Used to cool the roaster from Idle High Temperature down to Idle Low Temperature when the roaster is in a Machine State of Idle. Ramps the Burner up to 100% and opens the Roaster Door (Discharge Gate) to allow room-temperature air into the roaster. Temporary. Displays at the beginning of a roast, when using the Auto Charge setting. Indicates that roaster is waiting for the Return Air Temperature to reach the specified Charge Temperature. Page 58

59 Machine States, continued Machine State Charge Cooling Charge Green Wait TAP Profile Roast Manual Roast Burner Recipe Auto Air Cool Post Roast Cooldown FAULTED Notes Occurs at the beginning of a roast when using the Auto Charge setting. Indicates that the current Return Air Temperature is greater than the Auto Charge Temperature. Similar to Thermal Standby Cool, but conditioning the roaster to the Auto Trigger Cooling Turnaround Temp Setpoint below the Charge Temperature in preparation for a roast, rather than to the Idle Low temperature. Indicates that beans are dropping down from the Green Bean Hopper and entering the Drum Chamber. Displays during a roast immediately after green beans have entered the Drum Chamber. This causes the Bean Temperature reading to decrease. This Machine State indicates Waiting for Turnaround Point (TAP) until the Bean Temperature begins to rise. Indicates current roasting method. Displays during Profile Roast after Wait TAP. Indicates current roasting method. Displays during Manual Roast after Wait TAP. Indicates current roasting method. Displays during a Burner Recipe roast. Displays towards End of Roast (EoR) if Auto Air Cool is enabled. Displays immediately after a roast cycle is completed and continues until the Drop Roasted Door closes. Displays when Cool Down button is activated, in preparation for shutting down the roaster at the end of the day. Displays when a Machine Fault occurs. Page 59

60 Temperature Measures There are several temperature measures for the roaster, each with a factory-configured maximum allowable temperature. If any of these maximum temperatures are exceeded, the roaster will issue a Fault and enter a Machine State of FAULTED. The condition triggering the Fault must be corrected, and the Fault must be Cleared on the Faults and Warnings Dialog, prior to resuming roaster operation. All Warning temperature thresholds are user configurable on the Burner Settings Configuration Screen. The Fault temperature thresholds are hard coded, and cannot be changed. Temperature Sensor Locations 1. Return Air Temperature. Located on the front left side of the roaster. 2. Bean Temperature. Located at the front of the roaster, just below the Drum Chamber Viewing Window on the Roaster Door. 3. Stack Temperature. Located at the top of the Stack on the Cyclone. 4. Inlet Air Temperature. Located at the back of the roaster. Return Air Temperature Sensor Bean Temperature Sensor Front View Page 60

61 Temperature Sensor Locations, continued Inlet Air Temperature Sensor Back View Stack Temperature High- Limit Sensor (Backup Safety Feature) Stack Temperature Sensor, Main Back View Page 61

62 Inlet Air Temperature Refers to the air entering the back of the Drum Chamber after being heated in the Cyclone. If the Inlet Air Temperature exceeds specified levels, it means that the Cyclone is running too hot. Use the QUENCH PROCESS button, MANUAL AIR COOL button, or use the Burner % slider to turn down the Burner flame. Exceeding maximum levels will trigger a Warning or Fault condition as follows: Warning: 680 degrees F (360 degrees C) Fault: 695 degrees F (368 degrees C) Return Air Temperature Refers to the air that is exiting the Drum Chamber and is being drawn back towards the Cyclone Exceeding maximum levels will trigger a Warning or Fault condition as follows: Warning: 640 degrees F (338 degrees C) Fault: 650 degrees F (343 degrees C) Stack Temperature Refers to the exit temperature of the air leaving the Stack at the top of the Cyclone. Normally this is between degrees F ( degrees C) during roaster operation. Exceeding maximum levels will trigger a Warning or Fault condition as follows: Warning: 1650 degrees F (899 degrees C) Fault: 1700 degrees F (927 degrees C) Stack temperatures exceeding 1700 degrees F (927 degrees C) will trigger a special Machine Fault, which shuts off the Burner, opens the Roaster Door, and discharges roasted beans. The Burner cannot be re-ignited until the roaster has cooled off. Page 62

63 High Temperature Limit Thermocouple There is a second, independent Stack Temperature sensor that is dedicated as a High Temperature Limit thermocouple. This sensor is connected to an independent High Temperature Limit monitor that will shut off the roaster at 1700 degrees F, independently of the Stack Temperature Theromocouple that is connected to the roaster s controller (the PLC). If this device is triggered, simply power cycling the roaster will not clear it. Instead, it must be reset manually by opening the main electrical cabinet and pressing the High Temperature Reset button while the roaster is being powered on. Figure 23. High Temperature Reset High Temperature Reset Button Bean Temperature The Bean Temperatures displays on the Main Roast Screen as a green Profile line, and in the upper left corner of the screen. Exceeding maximum levels will trigger a Warning or Fault condition as follows: Warning: 515 degrees F (268 degrees C) Fault: 525 degrees F (273 degrees C) Process Temperature The Process Temperature refers to the Bean Temperature of the roast currently in process. Baseline Temperature The Baseline Temperature refers to a Roast Profile, which displays in white during a Profile Roast. Page 63

64 User-Configurable Settings Many of the pre-sets shown on the Main Roast Screen are user-configurable. Note that some settings require authorization or can only be performed by a Loring Factory or Field Technician. Customers needing access to certain features will be guided by Loring support personnel as needed, for diagnostics or other advanced functionality. Accessing the Configuration Screens To access the Configuration Screens: 1. Tap the MENU button on the Main Roast Screen in the upper left. 2. The Recipe Settings Configuration Screen appears by default, along with buttons on the left for the other Configuration Screens. 3. Tap the button for the desired Configuration Screen to access that screen. 4. Tap the ROAST button in the upper left to exit the Configuration Screens and return to the Main Roast Screen. Figure 24. Accessing the Configuration Screens Tap Menu button to access Left-hand buttons lead to individual Configuration screens Page 64

65 Recipe Settings Use the Recipe Settings Screen to load or save Roast Profiles. Burner Recipes are a legacy feature of the LCS v1 software, and are still available in v2; however, it is recommended to replace them with Profile Roasting. 1. The Name field shows the currently selected Roast Profile Name. 2. Tap the START THIS ROAST button to initiate a roast directly from this screen, using the selection displayed in the Name field. 3. Tap the CAPTURE LAST ROAST button to create another baseline, Profile Roast or Burner Recipe. 4. The SELECT buttons allow you to select a Baseline, a Burner Recipe, or a Profile Roast. After selection, the selected button turns green and the button name changes to show what is selected. For example, tapping SELECT PROFILE ROAST causes that button to change color and display as PROFILE ROAST SELECTED. Only one button can be selected (green) at a time. 5. Tap the LOAD button to load the selection. This button name changes depending on what was selected in the previous step. For example, if a Profile Roast is selected, this button will read LOAD PROFILE ROAST. 6. Tap the SAVE button to save the currently displayed curve according to what is currently selected: Profile Roast, Burner Recipe, or Baseline. The SAVE button name also changes based on selections made in the previous steps. Requires Level 2 user authorization. 7. Tap the DELETE A RECIPE button to delete a previously saved Roast Profile. Requires Level 3 user authorization. Page 65

66 Figure 25. Recipe Settings Configuration Screen Page 66

67 Roaster Settings The Roaster Settings screen allows the user to control the roaster Idle temperature ranges, as well as various timers and triggers such as the Lift Green Time, various Cooling times, and the Batch Size Correction Calculator. Refer to the onscreen help text for details on each of the Settings fields. 1. Use the Roaster Idle Temperature Controls to set the Idle High and Idle Low temperatures. 2. The Roast Timers and Triggers sets the time in seconds for various automated roast functions such as Lift Green, Charge Green, Chaff Quench, and Cooler Fan. 3. The Batch Size Correction Calculator lets you adjust the Initial Burner Setting Percentages (IBS%) and Charge Temperature for various Batch Sizes. The % Batch Size refers to the Maximum Batch Size for each roaster model. 4. The Maximum batch size can only be changed by an authorized Loring Factory Technician or Field Service Technician. Figure 26. Roaster Settings Configuration Screen Page 67

68 Screen Settings The Screen Settings screen controls units of measure, reporting, and whether to display the Log Color, Log 1st Crack, and Log 2nd Crack buttons during a roast. Other settings include Date and Time, and Clean Screen. Some settings require Level 3 or Level 4 user authorization. 1. Tap the SWITCH UNITS buttons to toggle between Imperial and Metric units for temperature and weight: degrees Fahrenheit or Celsius, and lbs or kgs. Requires Level 4 user authorization. 2. Tap the END OF ROAST ENABLED button to enable or disable automatic of roast reports. The button name changes to show ENABLED or DISABLED. Requires Level 4 user authorization. 3. Use the Roast Metrics CAPTURE buttons to display the LOG COLOR, LOG 1st CRACK, and LOG 2nd CRACK buttons on the Main Roast Screen. 4. Tap the LOGIN button to log in at a different user level and stay logged in. Note that function buttons on other screens requiring authorization will display a Login dialog to authorize for that function. 5. Use the CHANGE PASSWORD button under Security to change user passwords. Requires Level 6 user authorization (Loring Factory Technician). 6. Tap the SEND AN button to send a freeform to any desired recipient. 7. The TEST button allows you to send a test to the address entered on the System Settings Configuration Screen, in order to determine if the roaster s function is working, by verifying that the network and authentication settings are correct. 8. Tap the CLEAN SCREEN button to disable the Touchscreen for 15 seconds, in order to clean it. 9. Tap the SET TIME AND DATE button to change the system time, which is used to synchronize the Touchscreen time and the roaster controller (PLC) time. Requires Level 3 user authorization. 10. Tap the BACKLIGHT SETTINGS button to adjust the brightness of the Touchscreen s LED backlight. Page 68

69 Screen Settings, continued Figure 27. Screen Settings Configuration Screen Page 69

70 Setup Products Screen This screen allows you to configure bean products, in order to associate different types of beans with Roast Profiles. For example, you can organize products by origin, distributor, or any other factor as desired. Figure 28. Setup Products Configuration Screen Page 70

71 Diagnostics Screen This screen shows system diagnostics. A Loring Customer Support Technician may request you to access this screen or review information as part of troubleshooting. Figure 29. Diagnostics Configuration Screen Page 71

72 Burner Settings Screen Most Burner settings require Level 4 or Level 5 user authorization. Settings include Temperature Warning levels and Burner operational set points. Figure 30. Burner Settings Configuration Screen There are two thresholds that trigger a Warning and a Fault respectively. The Fault thresholds are a few degrees higher than the Warning thresholds. The Warning temperatures can be adjusted on this screen, but the Fault thresholds are factory-set and cannot be changed. Page 72

73 System Settings Screen System Settings allows a user to load a different system configuration (roaster settings), as well as configuring the roaster s IP addresses and accounts. Most settings require Level 3, Level 5, or Factory user authorization to access. 1. Tap the LOAD CONFIGURATION button to load a new configuration from the Touchscreen s local memory. 2. Use the Network and Setup buttons to assign network IP addresses for the roaster, the Touchscreen, the roaster report sender name, username, password, and IP settings, and roaster report list of recipients. Level 5 user authorization is required. 3. Tap the RESET SYSTEM button to restart the roaster control software without powering off the roaster. 4. Tap the LOAD DEFAULTS button to load factory default settings for the roaster. Level 5 user authorization is required. 5. The Revision number in the upper right may be required for troubleshooting. Figure 31. System Settings Configuration Screen Page 73

74 Auto Air Cool Settings Screen The Auto Air Cool Settings screen allows you to enable or disable Auto Air Cool, set the degrees before End of Roast (EoR) An additional feature allows you to set the maximum temperature at which the Auto Air Cool feature is allowed to run. Level 4 user authorization is required for this setting. WARNING: Setting this value too high could result in an unsafe condition with the beans nearing their lower explosive limit (LEL), and fresh oxygen being introduced into the Drum Chamber. Figure 32. Auto Cool Settings Configuration Screen Page 74

75 Auto Gate/Destoner Settings Screen (Optional) The Auto Gate feature is available on some roaster models, and allows you to automatically empty the Cooling Tray directly into the Loring Destoner, and run the Destoner on an automatic cycle at the end of a roast for a specified number of seconds. By default, the AUTO MODE ENABLED button set. Tap this button to turn the Auto Gate mode on or off. Figure 33. Auto Gate/Destoner Configuration Screen Page 75

76 Cold Stack Incinerator (CSI) Settings Screen (Optional) The Cold Stack Incinerator is a third-party accessory which is available on some roaster models, and requires Level 5 user authorization to access. Figure 34. Cold Stack Incinerator Configuration Screen Page 76

77 Switching Between Imperial and Metric Units This setting is located on the Screen Settings Configuration Screen, and requires Level 4 user authorization. From the Main Roast Screen, tap the MENU button and then the SCREEN button to access. Tap the SWITCH UNITS buttons under Screen Configuration for temperature and weight. Setting the Time and Date This setting is located on the Screen Settings Configuration Screen, and requires Level 3 user authorization. From the Main Roast Screen, tap the MENU button and then the SCREEN button to access. Tap the SET TIME AND DATE button to change these settings. Cleaning the Touchscreen This feature is located on the Screen Settings Configuration Screen. From the Main Roast Screen, tap the MENU button and then the SCREEN button to access. Tap the CLEAN SCREEN button. A temporary Clean Screen notice displays, with a 15-second countdown to allow you to wipe off the Touchscreen. User Levels, Privileges, and Default Passwords There are five levels of user built-in to the roaster control software. By default, the roaster is operated at the lowest level of user permission. Functions requiring a higher level of permission show a lock with a number corresponding to the required user level on the function button. Tapping the function button displays a login screen. Level0_Operator Used for normal roaster operation. No login required. Level1_Restricted Not used. Level2_RecipeEditor This user can save Roast Profiles and operate the roaster. The default password is Level3_SettingsAdministrator This user can delete files, Roast Profiles, and Burner Recipes, reset system access, and set the Auto Thermal Standby Count. The default password is Level4_ConfigurationEditor This user level is for customer personnel onsite who are responsible for configuration of the roaster, specifically the Burner settings. The default password is Level5_Administrator This represents the top level of customer access. It is also the owner/production manager who is also responsible for the setup of the machine in the factory. The default password is Level6_FactoryTechnician For Loring factory personnel only. Page 77

78 Alarms Alarms are machine-issued Warnings and Faults that require corrective action. When a Fault or Warning condition occurs, the Alarm Buzzer sounds and an Alert icon appears on the Main Roast Screen. Tap the FAULTS & WARNINGS alert button to open the Faults and Warnings dialog. Actions from this screen include: 1. Tap the CLEAR ALL WARNINGS button to clear the Warnings after correcting the problem. 2. Tap the CLEAR ALL FAULTS button to clear the Faults after correcting the problem. 3. Tap the CURRENT ALARM STATUS button to send an with the current status to the recipients entered on the System Settings screen. 4. Tap the ALARM HISTORY button to send an of the Alarm History to the recipients entered on the System Settings screen. 5. Tap the ALARM HISTORY button to view past Alarms. There is a button on the Alarm History screen to clear past Alarms. 6. Tap the SILENCE HORN button to shut off the Alarm Buzzer. Figure 35. Faults and Warnings Dialog Page 78

79 Alarm History The Alarm History dialog shows all Faults and Warnings since the last time the History was cleared. Figure 36. Alarm History Dialog Actions from this screen include: 1. Tap the CLEAR ALARM HISTORY button to clear the History. 2. Tap the Delete button (the X) to delete a selected Alarm. 3. Tap the ALARM HISTORY button to send an of the Alarm History to selected recipients. 4. Tap the CURRENT ALARM STATUS button to send an with the current status to selected recipients. 5. Tap the Back button (the arrow) to return to the Faults and Warnings dialog. Page 79

80 Location of Purge Proximity Switch LEDs Remediation for Faults and Warnings reference various indicators, including the Purge Gate Open and Close Proximity Switches. These indicators are located at the back of the roaster on the Purge Gate Air Cylinder. Purge Gate (opens inwards during Purge cycle) Purge Gate Air Cylinder For the Purge Gate alerts, check whether Purge Gate is open, and also check whether the Indicators match the actual position of the Purge Gate. Purge Gate Proximity Switch Indicator LEDs LEFT - Closed RIGHT - Open Page 80

81 Drop Door Override Push Button In addition to the Door Open button on the Touchscreen, the roaster has a manual push button to operate the Roaster Door. This button is located on the front left side of the roaster near the Cooling Tray. The button is very stiff and can be difficult to press manually. Use the rotating lever to press this switch if needed. Lever Drop Door Override Push Button Rotate Lever clockwise to depress the button Front Left View Page 81

82 Location of CAB and Gas Pressure Switches There are several switches with LED indicator lights that are referenced in the Faults and Warnings error messages. Some of these switches are inside of the Utility Tray at the back of the roaster. In order to view the status of the indicators on these switches, you must remove the back top panel of the Utility Tray and slide it off. The Combustion Air Blower (CAB) is a component that provides air to the Burner with the proper fuel/air mixture. The CAB pressure switch is used to determine if the CAB motor is on or off. The CAB Indicator LED is near the green Gas Mixer pipe where the Cyclone attaches. The High Gas and Low Gas Pressure Switches are used to indicate gas pressures outside of normal operating ranges. This example shows the configuration for Direct Spark Ignition (DSI) roasters. A Burner Control Unit (BCU) appears different. DSI/BCU option is determined by the roaster s shipping destination. Gas Mixer Combustion Air Pressure (CAB) Switch Low Gas Pressure Switch Regulator High Gas Pressure Switch Gas Valve Page 82

83 High Temperature Limit Controller Reset Button If the High Temperature Limit Stack Thermocouple detects a Stack Temperature that exceeds a preset warning threshold, you must use the High Temperature Reset Button to restart the roaster. This button is located inside the roaster s Electrical Panel. High Temperature Limit Reset Button Press and hold with the roaster powered on Front left view Page 83

84 Warnings A Warning means that action is required, but the roaster operator can still operate the roaster buttons on the Main Roast Screen. When a Warning occurs, an alert appears on the Main Roast Screen. To clear a Warning: 1. Correct the issue that generated the Warning. 2. Clear the warnings by tapping either the CLEAR ALL WARNINGS button on the Faults & Warnings Dialog or by tapping the Clear button on the Faults & Warnings Alert displayed on the Main Roast Screen. 3. Tap the ROAST button in the upper left to return to the Main Roast Screen. Table 2. Warning Messages Warning Text Purge Gate go to open exceeded timer setpoint Purge Gate go to close exceeded timer setpoint Bean Temperature High Limit Range Warning Inlet Temperature High Limit Range Warning Stack Temperature High Limit Range Warning Return Temperature High Limit Range Warning Low gas pressure during operation Corrective Action The Purge Gate is opening too slowly. Verify that the Purge Gate Open Switch LED is illuminated. Listen for air leaks. With the air pressure and roaster off, ensure that the Purge Gate operates smoothly without binding. Verify that air pressure is within range specified in the Pre-Installation and Site Preparation Guide. The Purge Gate is closing too slowly. Verify that the Purge Gate Closed Switch LED is illuminated. Listen for air leaks. With the air pressure and roaster off, ensure that the Purge Gate operates smoothly without binding. Verify that air pressure is within range specified in the Pre-Installation and Site Preparation Guide. The Bean Temperature exceeds the Warning level specified in the Burner Settings Screen. Use Manual Air Cool. The Inlet Air Temperature exceeds the Warning level specified in the Burner Settings Screen. Use Manual Air Cool. The Stack Temperature exceeds the Warning level specified in the Burner Settings Screen. Use Manual Air Cool. The Return Air Temperature exceeds the Warning level specified in the Burner Settings Screen. Use Manual Air Cool. Verify that the incoming gas pressure is within range specified in the Pre-Installation and Site Preparation Guide. Page 84

85 Warning Messages, continued Warning Text Combustion Air Blower on during ready Discharge gate showing open during roast mode Flame on when not commanded to be on Flame off when commanded to be on Purge gate is closed during cooldown Purge gate is open during green drop or start of roast or during profile Operator open auto door switch is stuck on BCU system is faulted and needs to be reset BCU ignite position is on when it should be off Corrective Action Check the LED indicator on the Combustion Air Blower (CAB) pressure switch. The CAB motor should not be running, and the CAB LED should not be illuminated when the roaster is in the Ready state. Indicates that the Roaster Door is open while a roast is in process. Check the Roaster Door. If it is not open, there could be a fault in the Roaster Door indicator switch. Check the Sight Glass on the Cyclone to see if the Burner is lit. If it is not lit, there could be a fault in the DSI or BCU unit. If Burner is lit, close the ball valve for gas at the back of the roaster to extinguish the Burner flame. Check the Sight Glass on the Cyclone for flame. If flame is on, there is a problem with the indicators. If it is off, try to relight the Burner. The Purge Gate should be open during Cooldown. Verify whether Purge Gate is open or closed. If it is open, check the Purge Gate Proximity Switch LED indicators. If it is closed, listen for air leaks. With the air pressure and roaster off, ensure that the Purge Gate operates smoothly without binding. Verify that air pressure is within range specified in the Pre-Installation and Site Preparation Guide. The Purge Gate could be stuck in the open position. Verify whether Purge Gate is open or closed, check the Purge Gate Proximity Switch LED indicators, and listen for air leaks. With the air pressure and roaster off, ensure that the Purge Gate operates smoothly without binding. Verify that air pressure is within range specified in the Pre-Installation and Site Preparation Guide. Check the Drop Door Override Push Button on the left side of the roaster and verify that the plunger button is not stuck in the Down position. Press it to verify that it operates. This indicates a problem with the Burner Control Unit (BCU). Check the numeric display on the BCU at the back of the roaster. A flashing display indicates an error. Note the number that flashes. Then clear the Warning, relight the Burner, and check this display again. During normal operation, the display should be steady and show 00 when flame is off, and 08 when flame is on and stable. Note the BCU flashing error code, clear the Warning, and see if it clears. If not, call Loring with the error code. DANGER: Do not attempt to open the Auto Gate directly with your hands, as it is powerful enough to sever fingers or cause permanent bodily injury. Page 85

86 Warning Messages, continued Warning Text BCU closed position is off when it should be on BCU open position is on when it should be off attempted to send but failed Burner failed to ignite Circulation Fan drive is off when requested on Auto Air Cool bean temperature exceeded Auto gate confirm open switch is not operating Auto gate confirm closed switch is not operating Auto gate auxiliary switch overridden Close drop roasted gate before trying to ignite the Burner External CSI System Warning External CSI Communications WD Drop External CSI Not Ready at Roast EOR Corrective Action Note the BCU flashing error code, clear the Warning, and see if it clears. If not, call Loring with the error code. Note the BCU flashing error code, clear the Warning, and see if it clears. If not, call Loring with the error code. Verify the setup under Screen Settings. Tap the TEST button to send a test . Check gas pressure. Try to relight burner. If problem persists, contact Loring. Open electrical cabinet and ensure the Circulation Fan VFD is powered on and does not have an alarm (ALM). The Bean Temperature has exceeded the threshold specified in Roaster Settings. Adjust Auto Air Cool settings to start at a lower temperature. The Cooling Tray Auto Gate is not operating. Tap the AUTO GATE button on the Touchscreen. (Option) The Cooling Tray Auto Gate is not closing. (Option) The Cooling tray Auto Gate manual switch is stuck on. Press the switch to see if it depresses and releases. (Option) This error is indicating the Discharge Door (Drop Roasted Door) is open while trying to light the Burner. The Cold Stack Incinerator (CSI) is a third-party piece of equipment. Contact the CSI manufacturer directly for support. Discontinue roasting until problem is fixed. (Option) Verify that the Cold Stack Incinerator (CSI) Ethernet cable is connected to the roaster. Otherwise, contact the CSI manufacturer directly. (Option) Indicates a problem with the Cold Stack Incinerator (CSI). Check for faults or warnings on the CSI panel, which is separate from the roaster Touchscreen. Power cycle the roaster and the CSI, and try again. Contact the CSI manufacturer directly for support. (Option) Page 86

87 Fault Conditions A Fault means that action is required, and the roaster operator cannot operate the roaster until the condition is cleared. A Fault causes the Burner to shut off, and the Machine State changes to FAULTED. Some faults may require aborting the roast or an Emergency Stop. To clear a Fault: 1. Correct the issue that generated the Fault. 2. Tap the CLEAR ALL FAULTS button on the Faults & Warnings Dialog. 3. Tap the ROAST button to return to the Main Roast Screen. 4. Tap the BURNER button to re-ignite the Burner. Table 3. Fault Messages Fault Text Purge gate go to open exceeded timer setpoint Purge Gate to close exceeded timer setpoint Utilities air supply - air is off Corrective Action The Purge Gate is opening too slowly or not at all, similar to the Warning. Verify that the Purge Gate Open Switch LED is illuminated. Listen for air leaks. With the air pressure and roaster off, ensure that the Purge Gate operates smoothly without binding. Verify that air pressure is within range specified in the Pre-Installation and Site Preparation Guide. The Purge Gate is closing too slowly, or not at all, similar to the Warning. Verify that the Purge Gate Closed Switch LED is illuminated. Listen for air leaks. With the air pressure and roaster off, ensure that the Purge Gate operates smoothly without binding. Verify that air pressure is within range specified in the Pre-Installation and Site Preparation Guide. Check the air supply ball valve at the back of the roaster, check the air pressure gauge on the roaster. Verify that air pressure is within range specified in the Pre-Installation and Site Preparation Guide. WARNING: Chaff Barrel may be hot if the Chaff High Temperature fault occurs. Handle with care when removing. Make sure the Circulation Fan is off. Page 87

88 Fault Messages, continued Fault Text Chaff high temperature switch is on Combustion Air Pressure switch DSI - Off during operation Utilities water supply - water is off High gas pressure switch is on Circulation fan not running during operation Discharge gate switch not showing closed Flame is on during purge sequence ESTOP Corrective Action Chaff Barrel is possibly on fire. Tap the Quench Chaff button, using as many times as needed. Make sure the Circulation Fan is off. Slowly remove Chaff Barrel from underneath Cyclone. Chaff Barrel may be hot. The Combustion Air Blower (CAB) Pressure Switch LED is off during operation, implying that the combustion motor is not running. Visually inspect the CAB switch and listen for the motor. Tap the BURNER button and try to re-light the Burner. Verify that Burner lights and CAB LED indicator turns on. Check the water supply ball valve at the back of the roaster, check the water pressure gauge on the roaster, and verify the actual water pressure against the specifications in the Site Preparation and Pre-Installation Guide. Check the roaster for water leaks. Verify water services with public utility or provider. Check the High Gas Pressure LED indicator. If LED is on, that indicates that gas pressure is not excessively high. If LED is off, there is high gas pressure. Check the gas pressure gauge on the roaster. Verify actual gas pressure against the specifications in the Site Preparation and Pre-Installation Guide. Next, power off roaster, shut off gas at the source (not the roaster), disconnect gas hose at source, open gas ball valve at back of roaster, let gas bleed out. Then reconnect hose at source, power on the roaster, and see if the LED light turns on (indicating gas pressure is not too high). Ensure proper ventilation prior to bleeding out excess gas into the room. Tap the CIRC FAN button on Touchscreen, and check that the Circulation Fan motor is running. Open electrical cabinet and ensure the Circulation Fan VFD is powered on and does not have an alarm (ALM). Indicates that the Roaster Door is open while trying to light the Burner. Check the Roaster Door. If it is not open, there could be a fault in the Roaster Door indicator switch. Visually inspect the Burner flame through the Sight Glass on the Cyclone. If the flame is not on, there could be a faulty DSI or BCU input. Operator has pushed the Emergency Stop Push Button on the roaster. Verify that the condition that prompted stopping the roaster has been corrected before releasing the Emergency Stop Push Button. WARNING: For High Gas Pressure Faults, ensure proper ventilation prior to bleeding out excess gas into the room, and avoid sources of potential gas ignition. Page 88

89 Fault Messages, continued Fault Text Purge gate is showing closed when it should be open Purge gate is showing open when it should be closed Drum drive is faulted BCU faulted during ignite sequence Bean thermocouple is faulted Inlet Air thermocouple is faulted Stack thermocouple is faulted Return air thermocouple is faulted BCU combustion air blower is on when it should be off Corrective Action Indicates that the Purge Gate is closed during the roaster Purge cycle. Verify whether Purge Gate is open. If it is closed, look for air leaks and verify that the Purge Gate Proximity Switch Closed and Open LED indicators match the actual condition of the Purge Gate. With the air pressure and roaster off, ensure that the Purge Gate operates smoothly without binding. Indicates that the Purge Gate is open during a roaster machine state where it should be closed. Verify whether Purge Gate is closed. If it is open, look for air leaks an verify that the Purge Gate Proximity Switch Closed and Open LED indicators match the actual condition of the Purge Gate. With the air pressure and roaster off, ensure that the Purge Gate operates smoothly without binding. Indicates that the motor for the Drum Paddle Drive is not running. Verify that the Drum Paddle Motor is not spinning. Verify that the Drum Drive Motor is running when the DRUM button is tapped on the Touchscreen. If applicable, ensure that the Drum Paddle VFD is powered on and does not have an alarm (ALM). Power cycle the roaster. The Burner is not lighting correctly. Visually inspect the BCU at the back of the roaster and look for a flashing number. Note this number and contact Loring. Leave the roaster powered on, as you may be asked to report the current Machine State to the Loring Support Technician. The Bean Temperature sensor is not reporting. Either it has failed, or there is a broken wire. Inspect thermocouple for damage. The Inlet Air Temperature sensor is not reporting. Either it has failed, or there is a broken wire. Inspect thermocouple for damage. The Stack Temperature sensor is not reporting. Either it has failed, or there is a broken wire. Inspect thermocouple for damage. The Return Air Temperature sensor is not reporting. Either it has failed, or there is a broken wire. Inspect thermocouple for damage. The Combustion Air Blower (CAB) switch should be off when the Burner flame is not lit. This Fault indicates that either the CAB switch is on when the Burner flame is off, the Burner flame is on when it shouldn t be, or that the CAB switch is stuck in the on position. Check the CAB switch LED. Page 89

90 Fault Messages, continued Fault Text BCU combustion air blower is not on during operation BCU ignite position is off during ignition BCU close position is on when it should be off BCU open position is on when it should be off Bean temperature too high fault Inlet Air temperature too high fault Stack temperature is too high fault Return air temperature is too high fault Corrective Action The BCU sees the Combustion Air Blower (CAB) switch is showing as off when trying to light the Burner, or when the Burner flame is already lit. When the Burner is being lit, the BCU needs to see the CAB switch transitioning from the off position to on. This fault can occur during Ignite and Stabilize states. Note the BCU flashing error code, clear the Fault, and see if it clears. If not, call Loring with the error code. Check the CAB switch LED. This fault can occur during Ignite and Stabilize states. Note the BCU flashing error code, clear the Fault, and see if it clears. If not, call Loring with the error code. This fault can occur during Ignite and Stabilize states. Note the BCU flashing error code, clear the Fault, and see if it clears. If not, call Loring with the error code. The Bean Temperature exceeds a factory-set Fault threshold. Use Manual Air Cool. The Inlet Air Temperature exceeds a factory-set Fault threshold. Use Manual Air Cool. The Stack Temperature exceeds a factory-set Fault threshold. Use Manual Air Cool. The Return Air Temperature exceeds a factory-set Fault threshold. Use Manual Air Cool. Page 90

91 Consolet Control Buttons and Indicators End of Roast (Amber indicator) 2. Alarm (Red indicator) 3. Flame On (Green indicator) 4. Power On/Off Selector Switch (Green indicator) 5. Alarm (tap the SILENCE HORN button on the Faults and Warnings Dialog to silence) 6. Emergency Stop (press to activate) Page 91

92 Fault Remediation Controls This section lists the various controls available in the case of a Fault or Warning. QUENCH CHAFF Button The QUENCH CHAFF button on the Main Roast Screen sprays a jet of water into the Chaff Barrel for as long as the button is pushed. A timed spray occurs at end of a roast. The timing can be changed on the Roaster Settings Configuration Screen. QUENCH PROCESS Button The QUENCH PROCESS button on the Main Roast Screen sprays a jet of water into the Cyclone for as long as the button is pushed. MANUAL AIR COOL Button The MANUAL AIR COOL button on the Main Roast Screen opens the Purge Gate and turns on the Cooling Fan. Tap once to turn on, and again to turn off. This can be used to cool the roaster off manually in preparation for the next roast. If the Burner is on, this button will also ramp the Burner to 100%. Page 92