Pancake Machine Operating Manual Model Series : PC -11 / PC-10S
!"#$%#$&' INTRODUCTION 1' OVERVIEW SAFETY PRECAUTIONS SAFETY HAZARD STATEMENT QUICK REFERENCE GUIDE 1' 1' 1' 2' 3' 4' 5' INSTALLATION 7' MACHINE COMMISSIONING AND OPERATOR TRAINING 7' MIX AND BATTER 9' Popcake® – 97% fat free pancakes The world’s first fully automatic pancake maker Belt technology HYGIENE AND SAFETY RULES BATTER PREPARATION RULES Water temperature Water volume Bagged premix BATTER PREPARATION PROCEDURES Inspecting the bag Adding water to the bag Shaking the bag Letting the bag
OPERATING MODES Power up mode Ready mode (making the pancakes) Make mode Cancel mode Power down mode MENU ITEMS Change size Change mix type Change bag Change colour Cake stack size Mini stack size Counter-Large Counter-Medium Counter-Minis Input belt code ERROR REPORTING 19' 19' 19' 20' 20' 20' 21' 22' 22' 23' 24' 24' 25' 26' 27' 27' 28' 28' CLEANING AND MAINTENANCE INSTRUCTIONS 29' SAFETY RULES CLEANING EXTERNAL SURFACES BELT CLEANING PROCEDURE SPLASH GUARD CLEANING CLEANING THE RUBBER WIPER LOCATED IN
INDEX 53' iii
3 ()*+,#%'-.%/)$,#0'()#1)2' '4'5#$/"61*$,"#' 1 5#$/"61*$,"#' !"#$"%#&' Popcake® – 97% fat free pancakes Popcake®, pancakes are the world’s first truly 97% FAT FREE pancakes. Popcake® pancakes are made from non-genetically modified natural ingredients. Popcake® pancakes can be served with a variety of delicious sweet and savoury toppings and fillings as well as a variety of complementary food items.
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3 ()*+,#%'-.%/)$,#0'()#1)2' '4'5#$/"61*$,"#' ()*#+,'-$#.)/+%012' Following are the safety measures when operating the machine: 1 This appliance is not intended for use by young children or infirmed persons unless they are adequately supervised by a responsible person to ensure that they can use the appliance safely. 2 Young children should be supervised to ensure that they do not play with the appliance. 3 Read all operating instructions before using machine.
3 4'5#$/"61*$,"#' '()*+,#%'-.%/)$,#0'()#1)2' 17 Do not place the machine on or near a hot gas or electric burner, or a heated oven. 18 Do not heat, or use flammable materials in or near the machine. 19 Do not use corrosive chemicals or vapours in machine. 20 Do not remove any panels or covers from the machine or tamper with any working parts as it could result in serious injury or death.
3 ()*+,#%'-.%/)$,#0'()#1)2' '4'5#$/"61*$,"#' 5 All error conditions reported by the machine are immediately actioned in line with the instructions given on the machine display and in this manual. 6 The machine is correctly maintained by operators in accordance with the requirements detailed and outlined in this manual and Quick Reference attached to the machine. 7 The machine is maintained by authorised distributors of the manufacturer in line with the maintenance service schedule for the machine.
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3 ()*+,#%'-.%/)$,#0'()#1)2' '8'5#&$)22)$,"#' 2 5#&$)22)$,"#' :).3%1#'.066%22%01%19')15' 0-#$)+0$'+$)%1%19' Every machine must be commissioned by an authorised distributor of the manufacturer. Before an operator can use the machine they must understand the purpose of the machine, the way it functions and be trained to safely operate it, either directly by an authorised distributor or by a person who has been trained and is qualified to train others.
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3 ()*+,#%'-.%/)$,#0'()#1)2' '9'(,?')#6'@)$$%/' 3 (,?')#6'@)$$%/' ;,9%#1#')15'2)*#+,'$/<#2' Hygiene is a vital part of ensuring the quality of the pancakes served. When preparing the batter the following simple rules should be followed: 1 Wash your hands thoroughly before commencing preparation. 2 Rinse the water bottle in hot water before use. 3 Avoid direct handling of premix and batter 4 Wear correct attire (including gloves) to undertake the preparation.
3 9'(,?')#6'@)$$%/' '()*+,#%'-.%/)$,#0'()#1)2' agents after the bag of batter has been loaded into the machine. This results in the bag “burping” when pancakes are being made. This “burping” can affect the size of the pancakes, but has no other effect. It is important to use clean, fresh drinking water at room temperature. NEVER USE COLD OR REFRIGERATED WATER. Water volume It is vital in making pancakes of consistent texture and size to use the recommended volume of water (655 ml / 22 fl oz).
3 ()*+,#%'-.%/)$,#0'()#1)2' '9'(,?')#6'@)$$%/' Inspecting the bag 1 Take a bag of premix from its storage place and inspect it for any obvious signs of damage or rupture. Ensure that the cap is correctly screwed to the bag nozzle. If it is damaged or ruptured or the cap is not correctly screwed on, do not use it, instead select another bag and repeat the inspection. 2 Open the lid of the cap and inspect it for any obvious signs of damage, i.e. tears in the membrane.
3 9'(,?')#6'@)$$%/' '()*+,#%'-.%/)$,#0'()#1)2' 3 Slap the bag down onto a flat surface, making sure that the nozzle is facing upwards twice or three times to infuse air bubbles into the batter. 4 As the contents of the bag are mixed, the bag fills with the raising agent’s natural gasses. 5 Unscrew the cap to release the as built up inside the bag. 6 Gently move a hand across the surface of the bag to ensure that as much gas as possible is removed from the bag.
3 ()*+,#%'-.%/)$,#0'()#1)2' '9'(,?')#6'@)$$%/' 4 Load the bag into the machine following the instructions on the control panel. >3)19%19')'?)9' Change bag procedures You may only use the manufacturers mix that has been prepared in accordance with the Mix Preparation Procedures. No other bagged batters or premixes of any kind should be used in this machine. Failure to comply will result in the manufacturer’s warranty being voided.
3 9'(,?')#6'@)$$%/' '()*+,#%'-.%/)$,#0'()#1)2' hole which is located in the floor of the bag chamber. Let the body of the bag lie on the floor of the bag chamber. 2 Slowly feed the batter away from the tail end of the bag by gently squeezing the batter up toward the middle of the bag and locate the tail of the bag between the two rods located in the bag chamber. It may be easier to first insert one side of the tail and then pull the rest of the tail through between the rods into position.
3 ()*+,#%'-.%/)$,#0'()#1)2' '9'(,?')#6'@)$$%/' :%@')15'?)++#$'2+0$)9#A'/2#')15' .)$#'$#.066#15)+%012' Dry Powder - premix Packaging Premix is supplied in 780 gram / 1.7 lb double-lined clear plastic bags fitted with caps and lids. Bags are sold in labelled cardboard boxes containing 20, bags with a gross weight of approx 15.6kg / 34.3 lbs.
3 9'(,?')#6'@)$$%/' '()*+,#%'-.%/)$,#0'()#1)2' Carrying and handling Boxes of bagged premix have a gross weight of 15.6 kg/34.3 lbs. Your internal OHS regulations must be followed when carrying and handling boxes of premix. Bags of premix or batter should be handled with care. They should not be thrown, ruptured or abused in anyway. The premix and batter contains some allergens, namely gluten, egg powder and milk powder.
3 ()*+,#%'-.%/)$,#0'()#1)2' ':'C&,#0'$+%'D)*+,#%' 4 C&,#0'$+%'D)*+,#%' The machine functions using a combination of operating modes that are contained in a menu system, accessed through the control panel keypad located on the bottom front panel of the machine’s case. B#,-)5'<),0/+')15'*/1.
3 :'C&,#0'$+%'D)*+,#%' '()*+,#%'-.%/)$,#0'()#1)2' C6#$9#1.,'2+0-' To turn off the machine at any time; Action / Detail Press and hold the POWER ON/OFF key for 3 seconds. The machine turns off all functions. However, the cooking plates remain hot for some time before they can be touched. Display Emergency Stop In 3,…2,...1 Seconds To avoid a batter spill after an emergency stop, open the lid and remove the bag from the chamber, if possible. (-#.
3 ()*+,#%'-.%/)$,#0'()#1)2' ':'C&,#0'$+%'D)*+,#%' !-#$)+%19'605#2' Power up mode The machine is starting up. Action / Detail Display Press the POWER ON/OFF key to turn the machine on. Popcake International The warming up process takes about 6 minutes. The bar graph fills as the temperature increases. The graph fills from left to right until the machine is at operating temperature.
3 :'C&,#0'$+%'D)*+,#%' '()*+,#%'-.%/)$,#0'()#1)2' has been cooked. Make mode The machine is making orders. Action / Detail Display Each make order is added to the total number of pancakes on order progressively. Making ## of ## E F After making the first pancake from the bag a bar graph will show on the display. Moving from right to left, the bar graph indicates the approximate number of pancakes remaining in the bag. The “F” on the right indicates FULL and the “E” on the left indicates EMPTY.
3 ()*+,#%'-.%/)$,#0'()#1)2' ':'C&,#0'$+%'D)*+,#%' Action / Detail Display Press the POWER key at any time, except when the lid is open, to enter the Power Down Mode. After all the pancakes are cooked the machine will proceed to unwind the bag. The bag will be unwound and a message is displayed: Please Wait Unwinding Bag Unload Bag Now Then Close Lid Follow the instructions in “Unloading a bag from the machine” on page 14 to remove the bag from the chamber.
3 :'C&,#0'$+%'D)*+,#%' '()*+,#%'-.%/)$,#0'()#1)2' Change size Pancakes may be made in three standard sizes, minis, medium and large. Change Size is accessed from the Ready Mode using the menu. The size change made applies even after the machine is turned off and on again. Action / Detail Display Press Menu. The Change Size menu is displayed: Press OK. A message is displayed: The current size of the pancake is displayed in the top row and the alternate sizes are displayed in the bottom row.
3 ()*+,#%'-.%/)$,#0'()#1)2' ':'C&,#0'$+%'D)*+,#%' Action / Detail Display Press Menu as many times as necessary until Change Mix Type is displayed: Change Mix Type? Press OK to accept. A message is displayed. Press CANCEL to return to your original display. Now Sweet Mix 1=Sweet 2=Savoury Press 1 for sweet or 2 for savoury. A message is displayed: Sweet Mix? Press OK to accept the new mix type. You are returned to your original display.
3 :'C&,#0'$+%'D)*+,#%' '()*+,#%'-.%/)$,#0'()#1)2' Action / Detail Display Press OK. You will be returned to the original display. Change colour The ideal colour of a pancake is a warm golden brown on both sides. Because of temperature and age of mix pancakes may vary in colour, however, adjustments can be made to the machine. Change Colour is accessed from the Ready Mode using the menu. The colour change made will remain in effect until the machine is next turned off.
3 ()*+,#%'-.%/)$,#0'()#1)2' ':'C&,#0'$+%'D)*+,#%' be produced. You can change the setting from 1 to 99 pancakes using this menu item. Cake stack size is accessed from the Ready Mode using the menu. The re-set cake stack size change stays until the machine is turned off at the power point. Action / Detail Press Menu as many times as necessary until the Cake Stack Size menu is displayed: Display Cake Stack Size? 02 If you wish to retain the factory setting, press CANCEL.
3 :'C&,#0'$+%'D)*+,#%' '()*+,#%'-.%/)$,#0'()#1)2' Action / Detail Display If you wish to retain the factory setting, press CANCEL. You will be returned to your original display. If you wish to adjust the number of mini pancakes produced, press the appropriate number(s) from 1 to 9. When you are changing numbers, the entire number is reset with the first keystroke and then the numbers are added from right to left. Once you have entered the required number, press OK.
3 ()*+,#%'-.%/)$,#0'()#1)2' ':'C&,#0'$+%'D)*+,#%' Counter-Medium This item displays the number of medium sized pancakes produced, since the last time the counter was reset. You can either view the number or reset the counter to zero. Counter-Medium is accessed from the Ready Mode using the menu.
3 :'C&,#0'$+%'D)*+,#%' '()*+,#%'-.%/)$,#0'()#1)2' Input belt code The belts must be changed every 60 bags of mix. Each set of new belts is supplied with a 12 digit belt code number. The machine will indicate on the display when the belts must be changed. Follow the procedure on the screen to correctly install the new belts.
3 ()*+,#%'-.%/)$,#0'()#1)2' ';'!2%)#,#0')#6'D),#$%#)#*%',#&$/1*$,"#&' 5 !2%)#,#0')#6'D),#$%#)#*%' ,#&$/1*$,"#&' ()*#+,'$/<#2' 1 Always follow the steps detailed in this procedure. 2 Wash your hands thoroughly before commencing the procedure. 3 Wear correct attire to undertake the preparation 4 Ensure that hair is adequately groomed and secured under a hair net or cap. 5 Ensure that items of jewellery are secure and unable to fall into the machine.
3 ;'!2%)#,#0')#6'D),#$%#)#*%',#&$/1*$,"#&' '()*+,#%'-.%/)$,#0'()#1)2' ><#)1%19'#@+#$1)<'2/$*).#2' The external surfaces, including the floor of the bag chamber and the inside of the lid and door should be wiped clean at least once each day and more often if required using a clean, soft and slightly dampened cloth. Cleaning the external surfaces should only be undertaken after the machine has been turned off and has cooled down. =#<+'.<#)1%19'-$0.
3 ()*+,#%'-.%/)$,#0'()#1)2' ';'!2%)#,#0')#6'D),#$%#)#*%',#&$/1*$,"#&' 6 Take the damp clean, soft, cloth in one hand and while holding it, place it in the machine, lightly touching the top cooking belt, at the end of the machine where the small white rollers are located. With the other hand, turn the rear top roller located at the other end of the machine in a clockwise direction. The top cooking belt will move forward in a clockwise direction rubbing against the cloth.
3 ;'!2%)#,#0')#6'D),#$%#)#*%',#&$/1*$,"#&' '()*+,#%'-.%/)$,#0'()#1)2' 4. The Splash Guard should be cleaned on a daily basis. ><#)1%19'+3#'$/??#$'&%-#$' <0.)+#5'%1'+3#'>$/6?'D$),' E22#6?<,' 1 To remove the wiper, open the front door of the machine. 2 With your right hand, pull gently inward and towards the right of the machine to slide the wiper and the Crumb Tray under the belt’s front roller. 3 Clean the wiper thoroughly using a damp clean cloth.
3 ()*+,#%'-.%/)$,#0'()#1)2' ';'!2%)#,#0')#6'D),#$%#)#*%',#&$/1*$,"#&' 2 The filter is located at the far left hand side and directly below the splash guard. It is white in colour and has a handle for easy removal. 3 Pull firmly towards you until the filter is completely removed. 4 Wash under hot water to remove any fat or dust build-up. 5 Dry with a clean cloth. 6 Reinstall the filter to its original position.
3 ;'!2%)#,#0')#6'D),#$%#)#*%',#&$/1*$,"#&' '()*+,#%'-.%/)$,#0'()#1)2' Fig. 1 Fig. 2 Fig. 3 5 Loosen the belt by sliding the belt tensioning lever from right to left, moving from its normal operating position to its maintenance position (Fig.3). 6 Remove the belt by evenly sliding it over the rollers and out of the machine. Rotating the belts clockwise as you pull the belts out towards you makes the process easier (Fig.4). Fig. 4 Installing a belt Fig. 5 Fig. 6 Fig.
3 ()*+,#%'-.%/)$,#0'()#1)2' ';'!2%)#,#0')#6'D),#$%#)#*%',#&$/1*$,"#&' 7 Tension the belt by moving the tensioning lever from its maintenance position (left) to its operating position (right)(Fig.3). 8 Input the belt code, if required, into the machine via the display panel “Input Beltcode”, following the instructions on page 28. ;0+'F<)+#')22#6?<,'$#60")<' -$0.#5/$#'GH(I'J'.
3 ;'!2%)#,#0')#6'D),#$%#)#*%',#&$/1*$,"#&' '()*+,#%'-.%/)$,#0'()#1)2' 8 At no time should the hot plates or hot plate assembly come into contact with fluids of any kind or be submerged in water or liquid cleaning solutions and under no circumstances should the hot plates or hot plate assembly be cleaned using a dishwasher. Any of the above will void the manufacturer’s warranty. 9 No cleaning agents or solvent solutions should be used in the cleaning process.
3 ()*+,#%'-.%/)$,#0'()#1)2' ';'!2%)#,#0')#6'D),#$%#)#*%',#&$/1*$,"#&' 2 The machine has been operated strictly in accordance with the instructions outlined in the Machine Operating Manual. 3 All technical servicing and repair of the machine has been conducted by the manufacturer and/or the manufacturers authorized distributor only. For all further information on Service or in the event of difficulties, please contact your nearest distributor which can be located by visiting our company website www.
3 ;'!2%)#,#0')#6'D),#$%#)#*%',#&$/1*$,"#&' '()*+,#%'-.%/)$,#0'()#1)2' performance of the batter may decrease and each pancakes rising ability in the cooking process will diminish. Q: HOW LONG CAN A POPCAKE BE STORED AFTER IT IS MADE? A: Popcakes can be stored in the refrigerator (at 4°C / 39°F) for up to 48 hours however, for best results “freshly cooked Popcakes are best”. Q: CAN I REHEAT A POPCAKE AFTER IT IS MADE? A: Yes.
3 ()*+,#%'-.%/)$,#0'()#1)2' ';'!2%)#,#0')#6'D),#$%#)#*%',#&$/1*$,"#&' A: The Following reason may have caused a large Popcake to be made 1. The cap was not screwed back onto the bag properly. 2. The size sensor may be miss-aligned or pushed too far in. 3. There is too much water in the batter and the batter is not viscous enough (almost the consistency of water) 4.
3 ;'!2%)#,#0')#6'D),#$%#)#*%',#&$/1*$,"#&' '()*+,#%'-.%/)$,#0'()#1)2' taken to ensure that no debris would get between the belt and the hotplate. Q: HOW OFTEN SHOULD THE SPLASH GUARD BE CLEANED AND WHAT IS THE BEST WAY TO CLEAN THE SPLASH GUARD? A: The Splash-guard should be cleaned daily. The best way to clean the splash-guard is to remove from the machine and rinse under hot running water or place the entire assembly in the top rack of the automatic dishwasher.
3 ()*+,#%'-.%/)$,#0'()#1)2' ';'!2%)#,#0')#6'D),#$%#)#*%',#&$/1*$,"#&' >01+).+%19'/2' Visit www.popcake.com for details of your local authorised distributor.
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:)%1+#1)1.#'(#$"%.%19'P#.0$5' Serial No: Date Location Count Manufacturers Representative Maintenance Servicing Record - rev200710.
3 ()*+,#%'-.%/)$,#0'()#1)2' 'I2"&&)/J' I2"&&)/J' Bag chamber The section at the top of the machine where the premix bag is inserted. The chamber may be accessed by opening the lid on the top of the machine. Batter The bag of pancake premix after water has been added Belt Two Teflon® coated belts positioned over the cooking plates that rotate during operation and transport the pancakes through the machine.
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