Carpigiani 191 PSP N Installation Manual

APPLICARE

TARGA

CARATTERISTICHE

INSTRUCTIONS - HANDBOOK

191 SP/USA

191 SP USA P

We wish to thank you for the preference granted to us by purchasing one of
CARPIGIANI machines.

To the best guarantee, since 1993 CARPIGIANI has submitted its own Quality
System to the certifi cation according to the international Standard ISO 9001,
nowadays its production has got UNI-EN-ISO 9001-2008 Certifi ed Quality
System.

Moreover, Carpigiani machines comply with following European Directives:

- “Machinery” Directive 2006/42/EC,

- “Low Voltage” Directive 2006/95/EC,

- “EMC” Directive 2004/108/EC,

- “PED” Directive 97/23/EC,

- Regulation 2004/1935/EC relating to “Materials and articles in contact with
foodstuffs”

CARPIGIANI

Via Emilia, 45 - 40011 Anzola dell'Emilia (Bologna) - Italy

Tel. [phone] - Fax [phone]

This manual contains a TRANSLATION OF THE ORIGINAL INSTRUCTIONS and may not
be reproduced, transmitted, transcribed, fi led in a data retrieval system or translated into other
languages, without the prior written permission of CARPIGIANI.
The purchaser has the wright to reprint it for his own offi ce use.
CARPIGIANI policy pursues a steady reasearch and development, thus it reserves the right to
make changes and revisions whenever deemed necessary and without being bound to previous
statements to the purchaser.

Issue: 3 Date: 2012/09

Issued by: AM Checked by: RF Approved by: RV

191 SP USA P_EN - 2012/09 - Ed. 03

Changes:

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INDEX

FOREWORD ....................................................................................................................... 5

INSTRUCTION HANDBOOK ................................................................................. 5

PURPOSE ...................................................................................................................5

HANDBOOK STRUCTURE .................................................................................... 5

ADDITIONAL DOCUMENTATION ....................................................................... 5

CONVENTIONAL SYMBOLS ................................................................................ 6

SYMBOLOGY QUALIFICATION OF THE STAFF ............................................... 6

SAFETY ..................................................................................................................... 7

WARNING ................................................................................................................. 7

SECT. 1 GENERAL

1.1 GENERAL INFORMATION ................................................................................. 9

1.1.1 MANUFACTURER'S IDENTIFICATION DATA ......................................... 9

1.1.2 INFORMATION ABOUT SERVICE ............................................................. 9

1.1.3 INFORMATION TO THE USERS ............................................................... 9

1.2 INFORMATION ABOUT THE MACHINE ......................................................... 9

1.2.1 GENERAL DATA ........................................................................................... 9

1.2.2 MACHINE LAY-OUT .................................................................................. 10

1.2.3 TECHNICAL FEATURES ........................................................................... 10

1.2.4 MACHINE SETS LOCATION .....................................................................11

1.3 INTENDED USE .....................................................................................................11

1.4 NOISE ......................................................................................................................11

1.5 STORING A MACHINE ........................................................................................11

1.6 DISPOSAL OF PACKING STUFFS .....................................................................11

1.7 WEEE.......................................................................................................................11

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SECT. 2 INSTALLATION

2.1 ROOM NECESSARY TO THE MACHINE USE .............................................. 13

2.2 MACHINE WITH AIRCOOLED CONDENSER .............................................. 13

2.3 MACHINE WITH WATERCOOLED CONDENSER ....................................... 14

2.3.1 WATER VALVE ADJUSTMENT ................................................................ 14

2.4 ELECTRIC CONNECTION ................................................................................ 14

2.4.1 REPLACEMENT OF POWER SUPPLY CORD ......................................... 14

2.5 REFILLING ........................................................................................................... 14

2.6 MACHINE TESTING ........................................................................................... 14

SECT. 3 DIRECTION FOR USE

3.1 MACHINE CONFIGURATION .......................................................................... 15

3.2 ELECTRONIC CONTROL KEYBOARD AND BUTTON FUNCTION ........ 15

3.3 SPIGOT HANDLE ................................................................................................ 17

3.4 "R" PUMP .............................................................................................................. 17

3.5 PRELIMINARY OPERATION, WASHING AND SANITIZATION ............... 18

3.6 STARTING THE MACHINE ............................................................................... 18

3.7 PRODUCTION ...................................................................................................... 18

3.8 PASTEURIZATION .............................................................................................. 19

3.9 OPENING PROCEDURES .................................................................................. 19

3.9.1 SANITIZATION OF THE LID AREA ......................................................... 19

3.9.2 DISASSEMBLY AND CLEANING OF COMPONENTS .......................... 19

3.9.3 REASSEMBLY OF COMPONENTS .......................................................... 19

3.9.4 EXTERNAL CLEANING OF THE MACHINE ......................................... 20

3.10 CLOSING PROCEDURES................................................................................... 20

3.10.1 PRE-ARRANGE THE MACHINE FOR A PASTEURISATION

CYCLE OVERNIGHT ................................................................................. 20

3.10.2 DISASSEMBLY AND CLEANING OF THE TANK COVER ................... 20

3.10.3 CLEANING THE TANK ZONE .................................................................. 20

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3.10.4 DISASSEMBLY AND CLEANING THE OIL DRIP DRAWERS .............. 20

3.10.5 SANITIZATION OF THE LID AREA ......................................................... 20

3.10.6 CLEANING AND SANITISATION OF THE OIL DRIP TRAY ................ 20

3.10.7 EXTERNAL CLEANING OF THE MACHINE ......................................... 20

SECT. 4 SAFETY DEVICES

4.1 ALARMS ................................................................................................................ 21

4.1.1 BLACK-OUT ............................................................................................... 22

SECT. 5 CLEANOUT DISASSEMBLING AND REASSEMBLING OF

PARTS IN CONTACT WITH THE PRODUCT

5.1 GENERAL DESCRIPTION ................................................................................. 23

5.2 WASHING CONDITIONS ................................................................................... 23

5.3 SUGGESTIONS ..................................................................................................... 23

5.4 HOW TO USE DETERGENT/SANITIZER ....................................................... 24

5.5 DAILY CLEANING ............................................................................................... 24

5.6 PROGRAMMED CLEANING TIME ................................................................. 24

5.7 DRAINING AND CLEANING ............................................................................. 24

5.8 DISASSEMBLING OF THE TANK MIXER ..................................................... 25

5.9 DISASSEMBLING MIX PUMP ........................................................................... 25

5.10 DISASSEMBLING OF THE DISPENSING DOOR .......................................... 26

5.11 DISASSEMBLING OF THE BEATER ............................................................... 26

5.12 WASHING AND SANITIZING OF COMPONENT PARTS ............................ 27

5.13 REASSEMBLING OF THE HOPPER MIXER ................................................. 27

5.14 REASSEMBLING MIX PUMP ............................................................................ 28

5.15 REASSEMBLING OF THE BEATER ................................................................ 29

5.16 REASSEMBLING OF THE DISPENSING DOOR ........................................... 29

5.17 SANITIZING THE WHOLE MACHINE ........................................................... 30

5.18 MIX PRIMING ...................................................................................................... 30

SECT. 6 MAINTENANCE

6.1 SERVICING TYPOLOGY ................................................................................... 31

6.2 WATERCOOLING ................................................................................................ 32

6.3 AIRCOOLING ....................................................................................................... 32

6.4 TABLE OF SPARE PARTS EQUIPMENT ......................................................... 33

SECT. 7 TROUBLESHOOT GUIDE

7.1 TROUBLESHOOT GUIDE .................................................................................. 35

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FOREWORD

INSTRUCTION HANDBOOK

Editing this handbook, it was taken into due account European Community directions on safety
standards as well as on free circulation of industrial products within E.C.

PURPOSE

This handbook was conceived taking machine users' needs into due account.
Topics relevant to a correct use of the machine have been analyzed in order to keep unchanged in
the long run quality features charachterizing CARPIGIANI machines all over the world.
A signifi cant part of this handbook refers to the conditions necessary to the machine use and to
the necessary procedure during cleanout as well as routine and special maintenance.
Nevertheless, this handbook cannot meet all demands in details. In case of doubts or missing
information, please apply to:

CARPIGIANI Via Emilia, 45 - 40011 Anzola dell'Emilia (Bologna) - Italy

Tel. [phone] - Fax [phone]

HANDBOOK STRUCTURE

This handbook is divided in sections, chapters and subchapters in order to be consulted more
easily.

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Section

A section is the part of the handbook identifying a specifi c topic related to a machine part.

Chapter

A chapter is that part of a section describing an assembly or concept relevant to a machine part.

Subchapter

It is that part of a chapter detailing the specifi c component of a machine part.

It is necessary that each person involved in the machine operation reads and clearly understands
those parts of the handbook of his/her own concern, and particularly:

 The Operator must read the chapters concerning the machine star-up and the operation of

machine components.

 A skilled technician involved in the installation, maintenance, repair, etc., of the machine must

read all parts of this handbook.

ADDITIONAL DOCUMENTATION

Along with an instruction manual, each machine is supplied also with additional documenta­tion:

 Part list: A list of spare parts which is delivered together with the machine for its mainte-

nance.

 Wiring diagram: A diagram of wiring connections is placed in the machine.

Before using the machine read carefully the instruction handbook.

Pay attention to the safety instructions.

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CONVENTIONAL SYMBOLS

CAUTION: ELECTRIC SHOCK DANGER

The staff involved is warned that the non-obsevance of safety rules in carrying out the operation
described may cause an electric shock.

CAUTION DANGER FROM HIGH TEMPERATURES

This warns the staff involved that failure to abide by safety rules in carrying out the operation
described involves the risk of burns and scalds.

WARNING DANGER FROM MOVING PARTS

This informs the staff concerned of the presence of moving parts and the risk of injury from failure
to comply with safety regulations.

CAUTION CRUSHING HAZARD

This warns the staff involved that failure to abide by safety rules in carrying out the operation
described involves the risk of suffering crushed fi ngers or hands.

CAUTION: GENERAL HAZARD

The staff involved is warned that the operation described may cause injury if not performed fol­lowing safety rules.

NOTE

It points out signifi cant information for the staff involved.

WARNINGS

The staff involved is warned that the non-observance of warning may cause loss of data and
damage to the machine.

PROTECTIONS

This symbol on the side means that the operator must use personal protection against an implicit
risk of accident.

SYMBOLOGY QUALIFICATION OF THE STAFF

The staff allowed to operate the machine can be differentiated by the level of preparation and respon­sibility in:

MACHINE OPERATOR

Identify unqualifi ed personnel, those without any specifi c technical abilities who are capable of
carrying out simple jobs, such as: operating the machine using the commands available on the
keypad, the loading and unloading of products used during production, the loading of any con­sumable materials, basic maintenance operations, (cleaning, simple blockages, controls of the
instrumentation, etc.).

MAINTENANCE ENGINEER

He/she is a skilled engineer for the operation of the machine under normal conditions; he/she is
able to carry out interventions on mechanical parts and all adjustments, as well as maintenance
and repairs. He/she is qualifi ed for interventions on electrical and refrigeration components.

CARPIGIANI ENGINEER

He/she is a skilled engineer the manufacturer assigned to fi eld interventions for complex jobs
under particular conditions or in accordance with agreements made with the machine's owner.

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SAFETY

When using industrial equipment and plants, one must be aware of the fact that drive mechanisms
(rotary motion), high voltage components, as well as parts subject to high temperatures may cause
serious damage to persons and things.
Who is in charge of plant safety must be on the look-out that:

 an incorrect use or handling shall be avoided;
 safety devices must neither be removed nor tampered with;
 the machine shall be regularly serviced;
 only original spare parts are to be used especially as far as those components with safety

functions are concerned (ex.: protection microswitches, thermostats);

 suitable personal protective equipment is worn;
 high care must be payed during hot product cycling.

To achieve the above, the following is necessary:

 at the working place an instruction manual relevant to the machine should be available;
 such documentation must be carefully read and requirements must conse quently be met;
 only adequately skilled personnel should be assigned to electrical equipment;

IMPORTANT!

One must be on the look-out that the staff does not carry out any operation outside its own sphere
of knowledge and responsibility (refer to “Symbology qualifi cation of the staff”).

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NOTE:
According to the standard at present in force, a SKILLED ENGINEER is who, thanks to:

- training, experience and education,

- knowledge of rules, prescriptions and interventions on accident prevention,

- knowledge of machine operating conditions,
is able to realize and avoid any danger and has also been allowed by the person in charge of
plant safety to carry out all kinds of interventions.

WARNING

When installing the machine, insert a differential magnetothermal protection switch on all poles
of the line, adequately sized to the absorption power shown on machine data plate and with
contact opening of 3 mm at least.

 Never put your hand into the machine, alike during production and cleaning operations. Before

carrying out any maintenance operation, make sure that the machine is in “STOP” position
and main switch has been cut out.

 It is forbidden to wash the machine by means of a bolt of water under pressure.
 It is forbidden to remove panels in order to reach the machine inside before having discon-

nected the machine.

 CARPIGIANI is not responsible for any accident that might happen during operation, clean-

ing and/or servicing of its units, if this warning has not been fully complied with.

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1. GENERAL INFORMATION

1.1 GENERAL INFORMATION

1.1.1 Manufacturer's identif cation data

The machine has a data plate carrying manufacturer data, machine type and serial number, as­signed when it is manufactured.
Copy of machine data plate to be found on fi rst page of this handbook.

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1.1.2 Information about service

All operations of routine maintenance are here described in section "Maintenance"; any additional
operation requiring technical intervention on the machine must be cleared with the manufacturer,
who will also examine the possibility of a factory technician fi eld intervention.

1.1.3 Information to the user

 The manufacturer of the machine is at user's disposal for any explanation and information

about the machine operation.

 In case of need, please call the local distributor, or the manufacturer if no distributor is avail-

able.

 Manufacturer's service department is available for any information about operation, and re-

quests of spare parts and service.

1.2 INFORMATION ABOUT THE MACHINE

1.2.1 General data

Counter-top machine to immediately produce and distribute soft express ice cream in one fl avor
available with pump to ensure a grater increase of volume.
CARPIGIANI recommends to always use high quality mix for ice cream production in order to
satisfy your customers, even the most hard-to-please ones. Any saving made to the prejudice of
quality will surely turn into a loss much bigger than the saving itself.

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Bearing in mind the above statements, please take heed of the following suggestions:

- Make your mixes yourselves from high quality natural ingredients or buy them from reliable
companies.

- Follow closely instructions given by your mix supplier for the preparation of the mixes.

- Do not alter your mix supplier's recipies, by adding, for instance, water or sugar.

- Taste ice cream before serving it and start selling it only if entirely satisfactory.

- Make sure your staff always keeps the machine clean.

- Have your machine serviced always by companies authorized by CARPIGIANI.

1.2.2 Machine layout

8

0

m

m

m

0

8

)

n

i

3

(

m

m

0

8

)

n

i

3

(

m

(

3

i

n

)

710 mm (28 in)

5

6

0

m

m

(

6

7

5

2

2

i

m

m

n

(

)

2

6

,

5

i

n

)

m

5

0

5

)

n

i

0

2

(

m

Fig. 1

1.2.3 Technical features

Hourly

MODEL

production *

120 ml - 0,03 gal

portions

191 P/SP N 250 12 1 380 3 60 2,1 143

* Hour output may vary depending on mix used
Performances featured by a room temperature of 25°C and a water temperature of 20°C.

Hopper

capacity

liters/gal

Flavors

Electrical supply

Installed

power

Volt Phase Cycle kW/Hp

Net

weight

Kg/lb

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1.2.4 Machine sets location

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Caption:

1 Control panel
2 Freezing cylinder front lid
3 Drip tray shelf
4 Mix tank cover
5 Oil drip drawer

5

Fig. 2

4

1

2

3

1.3 INTENDED USE

The machines must be used solely for the purpose described in chapter 1.2.1, "General informa­tion" within the functional limits decribed below.

Voltage: ±10%
Min air temperature °C: 10°C
Max air temperature °C: 43°C
Min water temperature: 10°C
Max water temperature: 30°C
Min. water pressure: 0,1 MPa (1 bar)
Max water pressure: 0,8 MPa (8 bar)
Max relative humidity: 85%

The machine has been designed for its use in places which are not subject to explosion-proof
standards; its use is thus bound to conforming places and normal atmospher.

1.4 NOISE

The steady acoustic pressure level weighed A in a working place alike by watercooled and by
aircooled machines is less than 70 dB(A).

1.5 STORING A MACHINE

The machine must be stored in a dry and dump-free place.
Before storing the machine, wrap it in a cloth in order to protect it against dust and else.

1.6 DISPOSAL OF PACKING STUFFS

When opening the packing crate, divide packing stuffs per type and get rid of them according to
laws in force in machine installation country.

1.7 WEEE (Waste Electrical and Electronic Equipment)

In conformity with the European Directives 2006/66/EC, on batteries and accumulators and waste
batteries and accumulators, and 2002/96/EC, also known as WEEE, the presence of the symbol on
the side of the product or packaging means that the product must not be disposed
of with normal urban waste. Instead, it is the user’s responsibility to dispose of
this product by returning it to a collection point designated for the recycling/treat­ment of electrical and electronic equipment waste. Differentiated collection of this
waste material helps to optimize the recovery and recycling of any reclaimable
materials and also reduces the impact on human health and the environment. For
more information concerning the correct disposal of this product, please contact
your local authority or the retailer where this product was purchased.

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2. INSTALLATION

2.1 ROOM NECESSARY TO THE MACHINE USE

The machine must be installed in such a way that air can freely circulate allaround.
Rooms for the approach to the machine must be left free in order to enable the operator to act
without constraint and also to immediately leave working area, if need be.

ATTENTION

Machines with aircooled condenser must be installed no closer than 8 cm to any wall

in order to allow free air circulation around the condenser.

NOTE

An insuffi cient air circulation affects operation and output capacity of the machine.

191 SP USA P

8

0

m

m

m

0

8

)

n

i

3

(

m

m

0

8

)

n

i

3

(

m

(

3

i

n

)

2.2 MACHINE WITH AIRCOOLED CONDENSER

Fig. 3

Machines with aircooled condenser must be installed no closer than 8 cm to any wall in order to
allow free air circulation around the condenser.

NOTE

An insuffi cient air circulation affects operation and output capacity of the machine.

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2.3 MACHINES WITH WATERCOOLED CONDENSER

To make the machine run, a watercooled machine must be connected to running water supply,
or to a cooling tower. Water must have a pressure of 1 Bar at least and a delivery at least equal
to the estimated hourly consumption. Connect inlet pipe marked by plate "Water Inlet" to water
supply installing a shut-off valve, and outlet pipe marked by plate "Water Outlet" to a drain pipe,
installing a shut-off valve.

2.3.1 Water valve adjustment

WARNING

If water valve must be retarded, this operation will have to be carried out by skilled personnel, only.
Valve adjustment must be carried out in such a way that no water fl ows when machine is off and
lukewarm water fl ows when machine is on.

NOTE:

Water consumption increases if temperature of entering water is above 20°C.

ATTENTION:

Do not leave the machine in a room with temperature below 0°C

without f rst draining water from the condenser.

2.4 ELECTRIC CONNECTION

Before connecting the machine to the mains, check that machine voltage indicated in data plate
corresponds with the mains (see sec. 1.1.1 point C).
Insert a differential magnetothermal protection switch adequately sized to absorption capacity
required (see sec. 1.1.1 point D) and with contact opening of 3 mm at least.

WARNING

Yellow/green ground wire must be connected to a good ground outlet.

Rotation direction by three-phased machines

The beater rotates anticlockwise. By gravity-feed machines, it is necessary to remove the plate
and check the direction of rotation, whereas by machines with pump you shall check whether the
mix comes out from delivery hole when removing the compression pipe.

Reversing rotation direction

To reverse the direction rotation, when wrong, it is necessay to interchange two of the three leads
coming from the circuit breaker.

2.4.1 Replacement of power supply cord

If the machine main cable is damaged, it must be replaced through a cable with similar fea­tures.
Replacement will have to be carried out by skilled technicians only.

2.5 REFILLING

Motor installed in the machine is of the type with lubrication for life; no action of checking/re­placing or topping up is necessary.
Gas fi lling necessary to the freezing system is carried out at CARPIGIANI works during machine
postproduction testing. If a gas addition happens to be made, this must be carried out by skilled
technicans, only, who can also fi nd out trouble origin.

2.6 MACHINE TESTING

A postproduction test of the machine is carried out at Carpigiani premises; Operation and output
functionality of the machine are thoroughly tested. Machine test at end user's must be carried
out by skilled technicians or by one of CARPIGIANI engineers. After the machine positioning
and correct connections, also carry out all operations necessary to functional check and test of
the machine.

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3. DIRECTION FOR USE

3.1 MACHINE CONFIGURATION

The machine has a motor to drive the beater, and a cooling system with water or air condenser.

Soft ice cream is prepared by f lling the tank with cold mix (+4°C) and starting the automatic
production cycle, until the ideal ice cr eam consistency set by CARPIGIANI is r eached.

Thanks to the pump or to the feeding needle, the mix enters the freezing cylinder already mixed
with air; ice cream is produced only when it needs to be served. The spigot head allows a single
portion of soft ice cream to be distributed. At the same time, the same amount of mix moves from
the hopper into the freezing cylinder.

191 SP USA P

Fig. 5

3.2 ELECTRONIC CONTROL KEYBOARD
AND BUTTON FUNCTIONS

Details of the panel are shown in the picture below.

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Fig. 6

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STOP button

STOP function selected and light indicator on: the machine is ready to receive all
the functions.
From Production, Storage and Pasteurization it is necessary to press Stop 2 seconds,
in order to have the machine in STOP and so avoid "touch" problems with the touch­sensitive panel.

PRODUCTION function (Prd)

When selecting this function the led lights up and the mix into the cylinder is freezed
until its set consistency (pre-set HOT setting) is reached.

CLEANING function (CLE)

When selecting this function, led lights up, the beater and the mix pump run, while
the refrigeration unit is off. This function is timed and ends automatically when the
set time (usually 3 minutes) is reached.

LOCK button

To clean the keyboard panel with a clean towel it is recommended to block the keys
of the keyboard as follows:
Push for 3 second the LOCK button, the respective led will fl ash indicating that the
keyboard is blocked. At this stage you can clean the keyboard without any risk. To
reactivate the keyboard push for 3 seconds the LOCK button, the led will get off.

PASTEURIZING function (PAS)

Pasteurization cycle will not start if the mix inside the hopper is below the minimum
level. The mix, both in hopper and in cylinder, is heated up to 65°C, held at this
temperature for 30 minutes, then cooled down to the storage temperature.

STORAGE function (Sto)

When selecting this function, led lights up and the machine stores the mix both in
hopper and cylinder at a pre-set temperature of +4°C. The display indicates mix
temperature in the hopper.

MIX LEVEL INDICATOR
On display you'll be able to see:

1. Mix Out

2. How many cup is as still possible to delivery (last cones)

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3.3 SPIGOT HANDLE

In order to dispense the product, place a cup or a cone under the spout and slowly pull down the
disepnsing handle (pos. 5). As son as the product comes out, twist the cup or the cone to form a
cone-shaped serving. When the portion has reached the desired size, close the dispensing handle
and quickly pull the cone or the cup down in order to sharpen the tip.

WARNING

It is important to keep the sensor (pos. 920) clean.

5

920

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Fig. 7

3.4 "R" PUMP

"R" pump allows, by changing position of regulator pos. 271, to vary proportions between air
and mix conveyed to the freezing cylinder; so, within certain limits, it allows overrun regulation
depending on mix used.
"R" pump regulator should be set to the middle position.
If, after dispensing a signifi cant number of cones, ice cream is too heavy and wet, you may move
the R pump regulator a notch at a time towards the right. If ice cream comes out of spigot mixed
with air bubles, then turn R pump regulator a notch at a time towards the left.

271

Fig. 8

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3.5 PRELIMINARY OPERATIONS,
WASHING AND SANITIZATION

Before starting the machine for the fi rst time, it is necessary to thoroughly clean its parts and
sanitize all parts coming into contact with the mix. To perform these operations see section 5 of
this manual.

3.6 STARTING THE MACHINE

After installing the machine according to the instructions contained in the chapter INSTALLA­TION, and after carefully cleaning and sanitizing the machine, proceed as follows:

Remove the compression pipe from bottom of the tank and place it in the sanitizing solution.

Prime Hopper:

• Retrieve 1 bag of mix from the walk-in refrigerator.

NB.: Mix to be poured at a temperature of 4-5°C.

• With the draw handle open, pour one bag of mix into the
hopper and allow the mix to pass also into the freezing
cylinder. The mix level in the tank must never reach the
pump (see photo) and more mix must be added when
the level goes below approximately 2 cms from the tank
bottom.

• When only a full strength mix is fl owing from the draw
spout, bringing with it eventual residues of sanitizer,
close the draw handle.

Fig. 16

Connect the mix pressure pipe:

• When the mix stops bubbling from the bottom of the hopper, take the mix pressure pipe
from the sanitizing solution and insert it in its position in the bottom of the hopper. Make
sure your hands are clean and sanitized.

• Rotate the compression tube in a clockwise direction towards the pump and connect it to
the pump and rotate the connection tube (pos. 207) to block it. The level of the mixture
in the vat must never reach the pump (see fi gure). It is also necessary to add mixture
when the level has dropped to approximately 2 cms from the bottom.

• Reposition the vat cover.

• Select the production function.

3.7 PRODUCTION

Dispense icecream without exceeding the machine production rate as shown in the table on page

13. If you do not exceed it, and provide to refi ll the machine with fresh mix, you can be sure you
will never have to stop selling, even during peak hours.
While your store is closed, set the machine to STORAGE mode.
You will save signifi cantly on energy consumption, as the compressor runs only for the time
strictly necessary in order to keep product at its correct temperature.
When you reopen the store, assure that the heat-treatment has been correctly completed and no
malfunction has occurred, set the machine to STOP and then to PRODUCTION. Within a few
minutes icecream will be back at the correct consistency for sale.
It is essential that you carry out CLEANING and SANITIZATION of the machine, every few
days, depending on bacteriological quality of your mix as well as on health regulations in force
in your country.
If the machine has been stopped a long time due to a power failure, it is necessary that you check
product temperature before starting the sale again; if the temperature is over +6°C, the machine
must be emptied, cleaned and sanitized, and fi lled up with new fresh mix at +4°C.

191 SP USA P_EN - 2012/09 - Ed. 03

- 18 -

3.8 PASTEURIZATION

When you stop production, mix in tank and in cylinder must be pasteurized: to do that, press
STOPand then SELECTION till the led relevant to PASTEURIZATION function switches on. The
machine can also be programmed to carry out pasteurisation automatically whilst the premises
are closed and on a time scale set in the programme of the machine (by the technician).
It is anyway necessary that the mix inside the tank is over the half of tank capacity (mean level
should be thus covered).
The machine automatically executed heating and cooling programs and then stores the product
at +4°C.
In the event of a black-out during the pasteurization cycle, the machine will automatically carry
out the program. On reopening your shop, assure that the heat-treatment has been correctly com­pleted and no malfunction has occurred, press STOP and then select the production function;
within a few minutes ice cream will reach its right consistency to be served.
In the event of extended power failure, it is utmost necessary that, before dispensing ice cream
again, the temperature of the mix inside the tank is checked, so as to pasteurize the mix in case it
is beyond 6°C. If the power failure lasts several hours, it is then necessary to clean the machine
and refi ll with fresh mix.

3.9 OPENING PROCEDURES

ATTENTION

Ensure that your hands are thoroughly clean and sanitized before proceeding with the

following operations.

191 SP USA P

• Check that the Pasteurisation cycle has been totally completed and that the message “END”
has appeared on the display. This message indicates that the pasteurisation process has been
completed correctly without interruptions and the machine is ready for production. Press the
Stop key and put the machine into production.

ATTENTION

If the Pasteurisation cycle has not been completed, the machine is blocked and access

cannot be gained to production. The mix has not been correctly pasteurized.

Check why the pasteurization has not been carried out by reading the alarm messages

on the display.

If necessary, contact Technical Assistance.

Press the Stop key and the arrow key to select the pasteurization function and carry out

a manual pasteurization cycle. If the pasteurization cycle is completed successfully, the

blockage automatically resets and the machine is ready to start production. No product

can be dispensed during the pasteurization cycle.

3.9.1 Sanitization of the lid area

• Fill a bucket with detergent/sanitizing solution. Immerse the brush into the

solution and accurately clean the dispenser zone, the dispenser spout, the
handle and the area surrounding the piston; then rinse with clean water.

• Spray detergent/sanitizing solution over the tap zone, handle, dispenser

spout and inside the lid hole; then rinse with clean water

ATTENTION

Do not spray sanitising solution directly onto the photocell

underneath the door.

3.9.2 Disassembly and cleaning of components

Remove the oil drip tray, the oil drip drawers and the tank cover. Wash,
sanitise and rinse them. Reassemble the components after sanitisation.

3.9.3 Reassembly of components

Reassemble the oil drip tray, the oil drip drawers and the tank cover after sani­tization.

- 19 -

191 SP USA P_EN - 2012/09 - Ed. 03

191 SP USA P

3.9.4 External cleaning of the machine

Using a clean and sanitised cloth, clean the door area, the front panel and
any other areas that come into contact with the product.

3.10 CLOSING PROCEDURES

ATTENTION

Ensure that your hands are thoroughly clean and sanitized before proceeding with the

following operations .

3.10.1 Pre-arrange the machine for a pasteurisation cycle overnight

- Open the lid and check the level of mix in the tank.

- Add mix if necessary. The LED of the tank level indicator must be off. The level of the mix in
the tank must never reach the pump.

- Ensure that the machine is in Distribution mode (the relative LED must be alight).

3.10.2 Disassembly and cleaning of the tank cover

Disassemble the tank cover and wash, sanitise and rinse it.

3.10.3 Cleaning the tank zone

Using a clean and sanitized cloth, accurately clean the external zone of the
tank. Ensure that no debris drops into the tank. Reposition the sanitized tank
cover on the tank.

3.10.4 Disassembly and cleaning the oil drip drawers

Remove the two oil drip drawers from the side of the machine. Wash, sanitise,
rinse and reassemble them.

3.10.5 Sanitization of the lid area

• Fill a bucket with detergent/sanitizing solution. Immerse the brush into the
sanitising solution and accurately clean the dispenser zone, the dispenser
spout, the handle and the area surrounding the piston.

• Spray sanitizing solution over the tap zone, handle, dispenser spout and
inside the lid hole.

• Rinse with clean water

ATTENTION

Do not spray sanitising solution directly onto the photocell

underneath the door.

3.10.6 Cleaning and sanitisation of the oil drip tray

After sanitising the door area, remove the oil drip tray and wash, sanitise
and rinse it. Replace it on the machine.

3.10.7 External cleaning of the machine

Using a clean and sanitised cloth, clean the door area, the front panel and
any other areas that come into contact with the product.

191 SP USA P_EN - 2012/09 - Ed. 03

- 20 -

4. SAFETY DEVICES

4.1 ALARMS

The machine is provided with a self- “CHECK“ indicating possible troubles with your
machine.
The “CHECK” led (the spot down on the right side of the display ) blinks when an alarm is
active, and it stays on as a reminder of an alarm occurred and reset.
When an alarm is displayed, check which one through the table below.

The machine can be used in the distribution mode also when an alarm has occurred, provided that
it is non critical one; otherwise the machine will not allow to enter in the distribution function; if
this is the case, press STOP and do not use the machine till its repair.
Press Selection in order to delete the writing with reset alarm.

In the table below you can fi nd list of available alarms:

ALARM DESCRIPTION

A01 (PTMA) Thermal protection tripped.

191 SP USA P

A02 (RTC/PTMC)

A03 (TESV) Tank Safety thermostat tripped.

A04 (TESC) Cylinder Safety thermostat tripped.

A05 (TEV)

Above 5 critical alarms cause machine to set at STOP, while led blinks if the alarm is still active
and is fi xed on if reset.

ALARM DESCRIPTION

A06 (TEC)

A07 (TGV)

Compressor thermal relay or Compressor thermal protection tripped.

Tank sensor faulty (interrupted or under short circuit).
You can only enter in Cleaning function.
The machine set at Stop.

Cylinder sensor faulty (interrrupted or under short circuit). If tripping
comes from Pasteurization or Storage, the machine will set at Stop.
If it comes instead from Cleaning or Production, the machine will
remain in that function: relevant led blinks and A06 will be displayed.

Tank evaporator sensor faulty (interrupted or under short circuit).
The alarm will cause check led blinking but will not stop the machine
(this remains in the same function).

A09 (IMS)

A11 (PRESS)

A12 (TE1)

A15
(BLACK OUT)

A20 (BELT)

Safety magnet switch.
Front lid open.

High pressure switch tripped. After 3 times or when it trips
2'consecutively, the machine sets at Stop.

Cylinder evaporator sensor faulty (interrupted or under short circuit).
The alarm will cause check led blinking but will not stop the machine
(this remains in the same function).

Blackout. The machine returns to the function where it was , excepted
for Cleaning, where it returns to Stop or Pasto Cooling according to
the Blackout Table.

DELTA TGVTEV
In Heating of Pasteurization, if TGV temperature becomes >= TEV as
to the value programmed in step DELTA TGVTEV, A20 is displayed
and the machine sets back at STOP.

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191 SP USA P_EN - 2012/09 - Ed. 03

191 SP USA P

ALARM DESCRIPTION

In Production: the beater motor is controlled and if staying ON more

A22 (TIME OUT)

A24 (MIX OUT)

than 15' without reaching HOT, the machine sets at "Hot reached"
status, with alarm A22. If, instead, the consistency value is below
HOB (HOT Block) 15', the machine sets at Stop.

When the minimum level is on (level LED on) and in Production we
dispense a number of portions same as or higher than the value set in
step t23 (Last Cones), A24 is displayed and the machine sets at Stor­age mode. Top up in order to reset the alarm.

A30

Wnn - WAS

Stb

PHS

LOW

If TEV is over 15°C in Stop, a Pasteurization cycle will be forced and
the display shows A30.

In production, everytime the beater motor starts, if we press the pro­duction key or we dispense an ice cream portion, Wnn is displayed,
this means that there are still nn days to the machine wash. See
WEEKLY CLEANING.
The last days to cleaning, the display is WAS, which will be reset
through the Selection key once the machine has been washed.
Also when:
the machine has been left 24 hours in Stop with mix level covered,
Cleaning is forced (WASH) and the alarm resets soon after the ma­chine wash (IMS).

In production, it may be displayed STB, meaning Stand By or ice
cream not yet ready for distribution.

Phase controller. Machine is left in Stop. It is necessary to invert 2
phases in order to enable its functioning again. On turning the ma­chine on, the alarm resets.

"LOW" blinks mix is out and reserve led is on. The alarm is active in
all functions but Cleaning.
An acoustic signal is activated in models PIZZA HUT and it plays till
mix topping up.

4.1.1 Black-out

In case of a blackout, if the machine was:

- in Stop or Cleaning, on power return it sets at STOP.

- Production, Storage or Heating or Pause during Pasteurization: on power return, the machine

sets back at the function where it was before blackout and alarm A15 will be displayed.

- Cooling step from Pasteurization,

on power return, the machine checks TEV temperature, as well as how long the blackout lasted;
if time turns to be longer than the one shown in the table, the machine will executed the full
pasteurization program again, whereas CHECK led is on and A15 is both on the display on and
events list.
If, on the contrary, time is shorter than the one shown in the following table, the machine will set
back at Cooling step from Pasteurization and A15 will be displayed.

Temperature TEV Time

65°C - 50°C 30 minutes

49°C - 15°C 10 minutes

14°C - 10°C 20 minutes

9°C - 4°C 2 hours

191 SP USA P_EN - 2012/09 - Ed. 03

- 22 -

5. CLEANOUT DISASSEMBLING AND REASSEMBLING OF
PARTS IN CONTACT WITH THE PRODUCT

5.1 GENERAL DESCRIPTION

Cleaning and sanitisation are operations that must be carried out habitually and with maximum
care at the end of each production run to guarantee the production quality and respect the
necessary hygienic norms.
Giving dirt the time to dry out can greatly increase the risk of rings, marks and damage to
surfaces.
Removing dirt is much easier if it is done immediately after use because there is the risk that
some elements containing acid and saline substances can corrode the surfaces. A prolonged
soaking is recommended.

5.2 WASHING CONDITIONS

• Avoid using solvents, alcohol or detergents that could damage the component parts,

the machine or pollute the functional production parts.

• When manually washing never utilise powder or abrasive products, abrasive sponges
or pointed utensils; there is a risk of dulling the surfaces, removing or deteriorating the
protective fi lm that is present on the surface and scoring the surface.

• Never ever use metal scouring pads or synthetic abrasives to stop any scouring action that
could remove ferrous parts that could cause oxidisation or make the surfaces vulnerable.

• Avoid using detergents that contain chlorine and its composites. The use of these detergents
such as bleach, ammoniac, hydrochloric acid and decalcifi ers can attack the composition of
the steel, marking it and oxidising it irreparably and causing damage to the “plastic” parts.

• Do not use dishwashers and their detergent products.

191 SP USA P

5.3 SUGGESTIONS

• Use a non-aggressive detergent solution to wash the parts.

• Manually wash the parts in water (max 60°C) using a non-aggressive detergent and the
cleaning brushes supplied as standard.

• Use drinking water (bacteriologically pure) to rinse the parts.

• To sanitise leave the disassembled parts in sanitised tepid water for the time specifi ed by the
manufacturer of the product used (use the sanitising product following the instructions
of the manufacturer) and rinse them before reassembling.

• When the washing procedure has been completed and before the reassembly of each
component dry thoroughly with a clean and soft cloth that is suitable for coming into
contact with foodstuffs, to avoid leaving any humidity rich in mineral salts and chlorine that
could attack the metal surfaces and leave opaque traces.

Carpigiani recommends the use of sanitising detergent to wash the machine.
The use of detergent/sanitizer permits optimising the washing and sanitising process inasmuch
that it eliminates two phases of the procedure (a rinse and a washing phase). Substantially,
the use of detergent/sanitizer saves time facilitating and simplifying the washing/sanitising
procedures.

ATTENTION

It is also essential that each time the machine is washed and parts in contact with the ice

cream mix are removed, to make a visual check of all parts in thermosetting materials,

plastics, elastomers, silicone and metal that come into contact with the product (for

example, scrapers, pump gears, beaters, etc…).

Each part must be whole, not worn and without cracks or splits, or opaque, if originally

polished/transparent.

Carpigiani refuses to accept any liability for damage caused through imperfection and/

or failures not found and promptly solved, including with the use of original replacement

parts, and is happy to provide help and consultation for all specif c customer requests.

- 23 -

191 SP USA P_EN - 2012/09 - Ed. 03

191 SP USA P

5.4 HOW TO USE DETERGENT/SANITIZER

Prepare a water-based solution and detergent/sanitizer following the instructions on the label
product used.

Washing/sanitizing by soaking

- Remove larger residues by hand.

- Remove fi ner residues with a jet of water.

- Soak the parts to be cleaned in the detergent/sanitizer solution.

- Leave the solution to act for the time specifi ed by the manufacturer of the product used.

- Rinse the parts with care, using plenty of clean drinking water.

5.5 DAILY CLEANING

Refer to the opening procedures (par. 3.9) and closing procedures (par. 3.10).

5.6 PROGRAMMED CLEANING TIME

The machine is equipped with an automatic system wich calls for washing of the parts in contact
with the product for example every 14 days.
This system, identifi ed as "WASH", disables the dispensing function
at the end of the fourteenh day after the latest cleaning. On the display,
the message " " appears.
Every time the product is dispensed or the beater motor is activated,
the display shows the number of days to the next cleaning date, as
follows:

DAY MESSAGE

3 days before -3

2 days before -2

1 day before -1

Disabling day

WARNING

Cleanout and sanitization must be carried out at the programmed date indicated on the

display (for example every 14 days), as a habit and with utmost care, in order to secure

quality of production in the observance of healthy rules.

5.7 DRAINING AND CLEANING

1. Place a empty pail under the spout.

2. Press the STOP button.

3. Pull the dispensing lever and drain the ice cream.

4. Select CLENOUT function.

5. When the product coming out becomes liquid, push STOP button and leave the spout open.

6. Remove the hopper cover.

7. In the hopper, disconnect pressure pipe from the mix pump, turn it sideways, remove it pull­ing it up from its seat and let the product fl ow completely out. Grasp the pump an turn it in a
clockwise direction of 45° then pull it out towards you.

8. Remove the hopper agitator by pulling it upwards.

9. Close the spout handle, pour 10 litres of cool and clean water into the mix hopper. Use the white
hopper brush to scrub the mix hopper, mix level sensor and the outside the agitator shaft. Use
the small brush to clean the mix inlet hole and the drive hub of the mix pump.

10.

Place an empty pail under spout. Open the spigot piston and let the water drain out.

11. Rinse with warm water until the solution runs clear.

12. Select CLENOUT function and let the beater run for 10 seconds.

13. Turn the machine off by pushing the button and let the water fl ow out.

Fig. 19

191 SP USA P_EN - 2012/09 - Ed. 03

- 24 -

5.8 DISASSEMBLING OF THE TANK MIXER

Remove the hopper agitator (pos. 162) by pulling it upwards.

162

Fig. 20

5.9 DISASSEMBLING MIX PUMP

1.

Keeping the feeding tube (pos. 271) upward turn it counterclockwise and pull it out.

2. Pull the spring (pos. 206) and the back fl ow valve (pos. 245) out. Using the o-ring extractor,
remove the o-ring (1126).

3. Unscrew the 2 knobs (pos. 8) and separate the cover (pos. 202) from the pump body (pos.

39).

4. Tapping the pump body against the palm of your hand, remove the pump gears (pos. 38 and
38A). Using the o-ring extractor, remove the large o-ring (pos. 1178).

5. Remove the pump body seal (pos. 243).

6. Pull the connection tube (pos. 207) from the pressure pipe. Remove the o-rings (pos. 1117,
1126 and 1131).

191 SP USA P

96

39J

39

243

248J

248

1178

38A

202

1117

207

1126

550

38

245

206

1126

271

8B

32

1131

Fig. 21

- 25 -

191 SP USA P_EN - 2012/09 - Ed. 03

191 SP USA P

28

21

24

25P

430

5.10 DISASSEMBLING OF THE DISPENSING DOOR

CAUTION

Before disassembling the dispensing head, make sure that the hopper

and the cylinder are completely drained.

1. Remove the two retaining knobs (pos. 8A) and pull the door assembly towards you sliding it
off the two front panel studs.

2. Pull the dispensing handle (pos. 5) so the piston (pos. 30) raises in its housing.

3. Remove the pivot pin o-ring (pos. 1285) and the pivot pin (pos. 6) out releasing the dispensing
handle (pos. 5).

4. Using the dispensing handle lever pull the piston (pos. 30) out completely.

5. Using the o-ring extractor, remove the two piston o-rings (pos. 1153), and the large dispensing
door o-ring (pos. 1188).

30

1188

1153

1285

7

8A

6

5

Fig. 23

5.11 DISASSEMBLING OF THE BEATER

Pull the beater (#21) out of the cylinder.
Slide the beater seal (#28) out of the beater shaft.
Pull out and remove the end pusher (#25P) and the idler (#24).
Remove the 3 beater blades (#430). Carpigiani suggests to replace the blades each 6 months.

191 SP USA P_EN - 2012/09 - Ed. 03

WARNING

The beater seal is very important. It must be checked regularly for wear and tear. It must

always be on the beater shaft and properly lubricated, during operation, otherwise mix

will leak in the drip tray.

- 26 -

5.12 WASHING AND SANITIZING OF COMPONENT
PARTS

1. Manually remove the bulk of the residue.

2. Remove the rest of the residue with a jet of water.

3. Wash the parts in the detergent/sanitizer solution.

4. Immerse the parts in the detergent/sanitizing solution for the time specifi ed by the manufac-
turer of the product used (use the detergent/sanitizing product following the instructions
of the manufacturer).

5. Rinse with clean water.

7. Place the components on a clean tray and let them dry naturally.

8. Immerse a brush in the detergent/sanitizing solution and clean the cylinder.

9. Immerse the brush in the detergent/sanitizing solution and clean the pump housing hole and
the compression tube.

10. Spray the sanitizing solution on the rear of the cylinder and on the walls of the tank.

Repeat operations 8, 9 and 10 several times, then rinse with clean water.

191 SP USA P

Fig. 26

5.13 REASSEMBLING OF THE HOPPER MIXER

Replace the hopper agitator (pos. 162) back in its seat: pay attention to angage it onto its shaft
correctly.

162

Fig. 28

- 27 -

191 SP USA P_EN - 2012/09 - Ed. 03

191 SP USA P

5.14 REASSEMBLING MIX PUMP

1. Lubricate and replace the o-ring (pos. 1117) on the connection tube (pos. 207).

2. Lubricate and replace the o-rings (pos. 1126 and 1131) on the pressure pipe (pos. 32).

3. Insert the connection tube assembly in the pressure pipe (pos. 32).

4. Lubricate and replace the punp body o-ring (pos. 1178) and the pump body seal (pos. 243).

5. Lubricate the sides as well as the center of the pump gears (pos. 38 and 38A) with a thin fi lm
of lubrifi cante insert them into the pump body (pos. 39). Do not lubricate the teeth of the

pump gears.

6. Lubricate and replace the o-ring (pos. 1412) on the feeding tube (pos. 271).

7. Hold the pump cover (pos. 202) upside down and insert the back fl ow valve (pos. 245) and
spring (pos. 206) in their pump cover housing.

8. Insert the feeding tube (pos. 271) in the pump cover: push and turn it clockwise.

9. Assemble the pump cover (pos. 202) with the feeding tube downwards onto the pump body
and turn the two knobs (pos. 8) tightly; install the mix pump in the hopper with the blocking
pin hook on the right, pushing and turning the pump in a clockwise direction and then in an
anticlockwise direction until it locks onto the hopper blocking pin.

96

243

550

39J

39

248J

248

1178

38A

202

1117

207

1126

38

245

206

1126

271

8B

32

191 SP USA P_EN - 2012/09 - Ed. 03

1131

Fig. 29

- 28 -

5.15 REASSEMBLING OF THE BEATER

28

21

24

25P

430

1. Insert the 3 beater blades (#430) onto the beater frame. Carpigiani suggests to replace the
blades each 6 months.

2. Insert the end pusher (#25P) onto the beater frame.

3. Insert the end of the idler shaft (#24) in the rear housing of the beater, through the end pusher.
Push the idler into position.

4. Lubricate the sides of the beater seal (#28) and slide it onto the beater shaft.

IMPORTANT

Check the beater seal for integrity. Replace if worn or damaged.

It should be replaced rather frequently.

5. Insert the beater assembly into the cylinder. Push it while turning it clockwise until it engages
in its rear hub, otherwise the dispensing head cannot be fastened properly, mix can fl ow out
and serious damage may occur.

191 SP USA P

5.16 REASSEMBLING OF THE DISPENSING DOOR

1. Lubricate and slide the 2 piston o-ring (pos. 1153) into their seats.

2. Insert the piston (pos. 30), pointed end down, in the dispensing head (pos. 7) making sure that
the piston square notch lines up with the rectangular opening on the spigot front.

3. Position the dispensing handle (pos. 5) on the door (pos. 7) and insert the pivot pin (pos. 6)
in its housing through the handle lever hole. Lubricate and insert the pivot pin o-ring (pos.

1285). Lubricate and slide into its seat the large dispensing door o-ring (pos. 1188).

4. Insert the dispensing door assembly onto the two front panel studs and fasten it with the two
knobs (pos. 8A) hand tight.

30

1188

1153

1285

6

5

7

8A

- 29 -

Fig. 32

191 SP USA P_EN - 2012/09 - Ed. 03

191 SP USA P

5.17 SANITIZING THE WHOLE MACHINE

The machine must be sanitized before mix is poured in. Procede as follows:

1. Fill the hopper to the maximum level with detergent/sanitizing solution prepared following
the instructions on the label product used, and allow to drain into the cylinder.

2. Using the brush, clean the mix level probes, the entire surface of the mix hopper, the surface
of the mix pump and the outside of the hopper agitator.

3. Select CLENOUT function and let the beater run for about 10 seconds. Press the STOP button.
The cylinder and the pump are now fi lled with the detergent/sanitizing solution.

4. Return to the machine with a small amount of detergent/sanitizing solution in a pail.

5. Dip the door spout brush in the pail of detergent/sanitizing solution and brush clean the dis­pensing spout. Repeat the operation 2 times.

6. Wiper the exterior of machine with clean sanitized towel. Repeat the operation 2 times.

7. Wait for at least 5 minutes before proceeding with the next instructions.

8. Place an empty pail under the draw spout and pull the handle.

9. Allow all of the sanitizier to drain. If the sanitizing solution does not fl ow out completely,
keep the spigot open and select CLENOUT function, keep the beater runnig for 5 seconds so
that the last solution residues fl ow out then push STOP.

CAUTION

Do not keep the beater running for more than the time strictly needed to complete

washing and sanitization. Without the lubrif cation of mix butterfatu

the beater wear out quickly.

10. Rinse by fi lling the cylinder with drinking water.

11. Drain the water from the cylinder by lowering the distribution lever.

5.18 MIX PRIMING

Prime Hopper:

• Take a bag of mixture from the refrigerator. Insert the mixture at a temperature of 4­5°C.

• Lower the distribution level and start to pour the mixture into the vat, permitting the mix
to pass also into the cylinder. The level of the mixture in the vat must never reach the
pump or the height of the feed needle; furthermore, it will be necessary to add mixture
when the level has dropped to approximately 2 cms from the bottom.

• Wait until a small quantity of mixture discharges from the opening, bringing with it any
sanitising residues and place the distribution level back in its original position, thereby
closing the opening.

Connect the mix pressure pipe:

• Continue to pour in mixture and wait until the fi lling of the cylinder has fi nished (during
the fi lling process, bubbles in the vat are visible). With clean and hygienic hands, take
the feed needle from the sanitised solution and insert it into the bottom of the vat.

• The level of the mixture in the vat must never exceed the height of the feed needle (see
fi gure); furthermore, it is also necessary to add mixture when the level has dropped to
approximately 2 cms from the bottom.

• Reposition the vat cover.

• Select the production function.

191 SP USA P_EN - 2012/09 - Ed. 03

- 30 -

6. MAINTENANCE

28

21

24

25P

430

6.1 SERVICING TYPOLOGY

ATTENTION

Any servicing operation requiring the opening of machine panels must be

carried out with machine set to stop and disconnected from main switch!

Cleaning and lubricatingmoving parts is forbidden!

“Repairs to the wiring, mechanical, air supply or cooling systems, or to parts of same

must be carried out by qualif ed personnel with permission to do so and if necessary,

according to the routine and extraordinary maintenance schedules as envisaged by the

customer with reference to specif c intervention methods, according to the use for which

the machine is destined”.

Operations necessary to proper machine running are such that most of servicing is completed
during production cycle.
Herebelow you can fi nd a list of routine servicing operations:

- Cleanout and replacement of stuff ng box

If the prodduct drips from the side drip drawer, it means that the stuffi ng box(pos. 28) has
no tightness.
When dismantling the beater, check the status of the stuffi ng box; based on how long the

machine has been used, replace it if necessary, alternating it with the second stuffi ng box,
provided with the accessories packet included in the packing.
If the stuffi ng box has no defects, it can still be used after washing it, i.e., when at room tem-
perature, it has again its original shape.
To replace the stuffi ng box, proceed as follows.
Remove the beater unit.
Remove the stuffi ng box from its slot.
Lubricate the replacement stuffi ng box.
Mount the new stuffi ng box.
Clean and lubricate the replaced stuffi ng box and store it to allow it to regain fl exibility.

191 SP USA P

WARNING

If you continue to work after noting traces of product in the drawer, you further

accentuate the leakage of the stuff ng box; this can lead to a malfunction

of the machine serious enough to halt production.

drip drawer

Fig. 34

- 31 -

191 SP USA P_EN - 2012/09 - Ed. 03

191 SP USA P

WARNING

Like all moving parts, the complete beater is also subject to wear and tear. For this

reason, we recommend checking the amount of wear to parts in direct contact with one

another (beater/beater idler and beater/cylinder walls) on a regular basis during

scheduled cleaning operations and in any case, every six months of machine operation.

In particular, make sure that the wear on the bushing on the beater idler is no more than

2 mm, as indicated by the marking on the bushing itself. If there is more than 2 mm

wear, it is necessary to replace the beater idler.

- Cleanout of beater assembly, cleanout of pump or feeding needle, cleanout and sanitiza­tion of the all machine

According to procedures described in section 5 of this manual.

- Cleanout of panels

To be carried out daily with neutral soap, seeing to it that cleansing solution never reaches

beater assembly at its inside.

WARNING

Never use abrasive sponges to clean machine and its parts,

as it might scratch their surfaces.

6.2 WATERCOOLING

By machines with watercooled condenser, water must be drained from condenser at the end of
selling season in order to avoid troubles in the event that the machine is stored in rooms where
temperature may fall under 0°C.
After closing water inlet pipe, withdraw drain pipe from its seat and let water fl ow out from
circuit.

6.3 AIRCOOLING

Clean condenser, periodically, so as to remove dust, paper and what can prevent air from circulating.
For cleanout, use a brush with long bristles or a bolt of compressed air.

ATTENTION!

When using compressed air, put on personal protections in order to avoid accidents;

put on protective glasses!

NEVER USE SHARP METAL OBJECTS TO CARRY OUT THIS OPERATION. GOOD
WORKING OF A FREEZING PLANT MOSTLY DEPENDS ON CLEANING OF CON­DENSER.

191 SP USA P_EN - 2012/09 - Ed. 03

- 32 -

6.4 TABLE OF SPARE PARTS EQUIPMENT

191 SP USA P

1188

475

772
772A
772C
772D

28

1117

1266

1178

1126

830

Pos. Description

28 Beater stuffi ng box
72 O ring extractor
475 Accessories
772 Swab D 8x250
772A Swab D 15x350
772C Swab D 20x450
772D Swab D 30x640
830 Food-grade lubrifi cant tube

840

1131

1153

72

Fig. 37

Pos. Description

840 Cleaning spatula
1117 Gasket OR
1126 Gasket OR
1131 Gasket OR
1153 Gasket OR
1178 Gasket OR
1188 Gasket OR
1266 Gasket OR

- 33 -

191 SP USA P_EN - 2012/09 - Ed. 03

191 SP USA P

191 SP USA P_EN - 2012/09 - Ed. 03

- 34 -

7 TROUBLESHOOT GUIDE

191 SP N

IRREGULARITY

Compressor starts and
then stops after a few
seconds.

Mix or ice cream come out
above or below piston though
it is closed.

Mix coming out of drip
drawer

Piston hard to operate.

Ice cream comes out fr om
front lid .

Low ice cream overrun

CAUSE

1. If machine is watercooled:
water is not circulating.

2. If machine is aircooled: air is not
circulating.

1. Piston without OR or OR is worn­out.

1. Stuffi ng box missing or worn-out.

1. Dry sugar on piston.

1. OR missing or not properly fi t.

2. Front lid knobs not tightened
evenly.

1. "R" pump not properly adjusted

PROCEDURE TO FOLLOW

1. Open water inlet cock and check that pipe is
not squashed nor bent.

2. Check that machine clearance is at least 80
mm from wall.

2. Call for service if necessary

1. Stop the machine and insert or replace it with
a new one if worn-out.

1. Stop the machine and install it if missing. If
worn-out, replace it with a new one.

1. Stop the machine and wash thoroughly and
grease piston and OR with edible fat.

1. Stop the machine and check and put remedy.

2. Stop machine. loosen and tighten them again.

1. Change regulator (Pos. 271).

- 35 -

191 SP N_EN - 08/06 - Ed. 07